Foam Props

We build Custom Foam Props

Table of Contents

Tradition + Technology

Imagine yourself at your favorite theme park, dancing with the characters from your favorite movie. The stage is set – brightly colored props create the perfect scene, the music begins, the lights come on, and the emcee welcomes Captain Hook and Mr. Smee to the stage. Foam props create amazing sets for movies, theater performances, sporting events, theme parks and museum displays. Large foam props with spectacular design elements are used in museums, movies, trade shows, and conventions. Foam stage props not only add to the atmosphere and bring theatrical performances to life, they add the wow factor you’re looking for at trade show booths and conventions and are sure to draw a crowd.

Character Props

Foam Character Sculptures

Custom foam props are one of a kind models and are great attention-grabbers. Larger-than-life foam character sculptures like alien fighting machines from War of the Worlds, superhero characters, Tiki Totems, dragons, dinosaurs, and video game characters you see at trade shows, fan conventions and theme parks immerse you in the experience and create vivid and lasting memories for audiences of all ages. Giant foam props include museum sculptures, exhibits, hanging models, architectural sets, décor, large product replicas, cartoon models and character models.

Foam props are generally light weight yet strong and durable. They can be sculpted in myriad sizes and shapes from small two-foot models to 20 feet or more. These crowd magnets are great for capturing selfies to share on social media and will be talked about for years to come. Creating the perfect props is only limited by your imagination.

3D Background Props

Foam Architectural Sets

Foam is used to create all sorts of architectural sets that are cost effective and lightweight – from large monument signs to faux stone walls; from stage prop arches like the ones we created for the Disney Villain Dance Party to full-size cemetery arches for the perfect haunted hollow; from scale models of Big Ben to gargoyle pillars; from castle walls and faux rocks to statues and scenery for movie, TV and Broadway sets. Foam can also be used to create architectural scale massing models.

Just like the Magic is Might statue from Harry Potter, many movies and TV shows have incorporated foam props in their sets and in the scenery to create the magic, drama and adventure we all enjoy. Here are just a few examples: Night at the Museum, The Lord of the Rings, Star Trek – The Next Generation, Smallville, Battlestar Galactica, Ghostbusters, Batman, Star Wars, James Bond, Pirates of the Caribbean, CSI: Miami, Alien and Jaws. Broadway shows like Phantom of the Opera, Les Misérables, Beauty and the Beast, The Lion King, Mary Poppins, The Little Mermaid, and Blue Man Group have also used foam scenery.

Foam is also used to create myriad architectural elements in new construction from columns, trim, crown molding, arches, caps, brackets, special molding, ceiling accents, railings, shutters, louvres, corbels, medallions, sills, cornices, keystones, and panels to outdoor pools, fireplaces, exterior features, theme rooms and landscaping accessories. Foam props have many finish options from faux marble to bronze-like and can be custom painted to match your color palette.

Hand Props

Technology and Materials

Today’s technologies are making more impressive next-generation models that have a variety of applications like giant shoes, thrones, and selfie backgrounds. Combining tried-and-tested technologies of foam sculpting, cutting, new 3D printing capabilities, state-of-the-art electronics and special effects model makers create some pretty awesome models.

  • Professional Creations — We have a team of designers, 3D artists, model-makers, painters, air-brushers, sculptors, carpenters, and welders to fabricate that imaginative, immersive, and experiential 3D foam prop model. You can also add special effects like custom electronics, lighting, and sound.
  • No project is too large, from a 2′ small statue to a large 50′ tall animal sculpture. If you can design it, we can create a physical model of it. If you can’t design it, we have a team of design professionals who can. We can work with preparing 3D models from scans, drawings, photos, and even sketches on napkins.
  • Technologies at Whiteclouds include Foam Fabrication, Hot Wiring, CNC Cutting, Laser Cutting, Welding, and six different 3D Printing technologies for rapid prototyping or production models.
  • With 3D printing technology, you aren‘t limited to straight lines and boxes. A 3D printer can easily create detailed, complex shapes. We use six different 3D printing technologies using different materials including UV-cured resin. The type of physical end-product determines which material will produce the best results. We can help you choose the material that is best for your project. Resolution on our printers is finer than a human hair. Our color 3D printers can print in full color (over 750,000 variations of color) for awe-inspiring reality.
  • Foam themed modelsfoam lettersfoam architectural models, foam props, foam characters, and foam sculptures can all be used to help expand what you are trying to build with foam fabrication.
  • Portability and/or mobility may be an issue, especially with trade show displays.
  • Our in-house spray booth gives us flexibilty in different types and grades of paint and finishing capabilities. Some finishes include latex, acrylic, urethane, polyurea, epsilon, polyurethane, and many others.
  • Did we mention, we have 60,000 square feet of production facilities in Utah, including the largest capacity of full-color 3D printing in the world.
Foam Blocks
Large Foam Blocks


Custom themed thrones can be the perfect backdrop prop for selfies, photos opps, trade shows, conventions, etc.


The cost of foam props depends on the volume of materials needed (size of the model), type of materials, the time it takes to create the 3D design, production labor, installation time and materials, and other elements unique to the project. Each foam prop model is bid individually. The .best way to determine cost is to email us, call us at 385-206-8700, or fill out the form below and let us bid on your project.

Get a Free Price Estimate for 3D Props

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Custom Fabrication Workflow

Common Questions

  • What file type is required to make a foam prop?
    We work with all architectural CAD programs and modeling programs including AutoCAD, Revit, Chief Architect, ArchiCAD, Maya, 3DS Max Design, ZBrush, and Sketchup, just to name a few. If you design in 3D, we will start with your 3D files. If you have 2D blueprints and elevations, or artist’s sketches, we can build a display/model from these files as well. If all you have is an idea or a napkin drawing, we can start with that.
  • What is the material used?
    We match the correct material and fabrication process to your requirements in terms of presentation, size, and transportability. We fabricate in our model shop using different types of foam, wood, metal, resins, and acrylics. We can also 3D print in uv-cured resin, plastic, rubber-like acrylic, and nylon.


  • What is the largest foam prop you can make?
    There is no limit to the size of model. Transportability will be your only concern on an extremely large foam prop.


  • What is the turnaround time for a foam prop?
    This depends on the features of the model itself as well as the scale of the model. We usually ask for six to eight weeks from the time we take the order to when you will receive the prop. Large projects can be four to six months or longer. We understand that sometimes deadlines are tight and we can accommodate rush orders but there is extra fees involved.


  • What technology do you use for foam props?
    It can be a number of different technologies, individually or combined. These range from 3D Foam, 3D Printing, CNC Cutting, laser cutting, laser etching, casting, molding, sculpting, painting, airbrushing, laminating, vinyl printing, and woodworking – all meant to produce highly engaging props that fit your exact needs.


  • What features can a foam prop have?
    Besides the physical 3D foam prop with the proper color and appearance, you can elect to ask for special lighting, sound, and movement.


  • If I want a second foam prop is it cheaper?
    Our pricing is based on the fabrication costs and the time it takes to prepare your design. The second prop is less in pricing because the design portion is complete.


    Do you have a question we didn‘t answer? Don’t hesitate to contact us at 1-385-206-8700 or [email protected].

Wire fram closeup Halo Master Chief
Digital wireframe of Master Chief from Halo video game
Creating 3D digital model King and Queen Kauai
We will create the 3D digital model and submit for approval.
Bronze airbrush 3D printed king and quenn kauai statue
This model was airbrushed with a bronze paint satin finish then clear coated for extra protection.

Worldwide Delivery

WhiteClouds has delivered models around the world.

History of Foam Props

Props were initially known as theatrical properties and were used on stage or screen by actors. They can be moved around and are generally portable and light-weight. As early as 1425, “properties” as they were called, were used in the play, The Castle of Perseverance. The first usage of the short version of the word “props” was found in the Oxford English Dictionary in 1841 and the singular “prop” in 1911.

Props started out as ordinary objects like coffee cups, telephones and the like but due to several factors like their size, color under stage lighting, and how durable they were didn’t do the job like they should have. So, they were replaced with specially designed props that look more realistic and are safer for the actors to use.

For example, prop weapons used for battle scenes and simulated combat look real and functional but lack the harmful factor are either non-functioning or have been modified with safety features so they’re not dangerous. There are stunt props that have breakaway pieces made of foam, balsa-wood furniture and sugar glass which is made of crystallized sugar to look like real glass.

Today, foam props are used to create entire movie sets, realistic scenery and buildings, theater background sets, rocks and other landscape features, amusement park backgrounds and structures, selfie backgrounds, haunted displays, mascots, museum exhibits and trade show displays. Foam props come in a variety of shapes and sizes from smaller household objects like frying pans, irons, hammers, and guns to large foam props like Captain Kirk’s chair on the Starship Enterprise for Star Trek (2009) and some even include special effects like touch-sensitive electronics or area-sensitive audio and lighting elements.

The future looks bright for foam props due to their versatility and they’re more economical to produce. Some movie props, like C3PO’s costume and the hilt of Kylo Ren’s lightsaber from Star Wars: The Force Awakens, are now being created with 3D printing.

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