In the age of highly targeted marketing, advertisements and product images have shifted from large roadside hoardings to in-store displays and department store windows.
Your product must be visible on shop walls, glass surfaces, racks, and even on the side surfaces of the cash counter. And the best way to showcase your product images, business offerings or services is by displaying them on custom-printed foamsheets, also known as sunboard prints or foam core prints.
Our Sunboard prints are images reproduced at extremely high resolutions on a thick, rigid, flat, and very smooth sheet of plastic. This PVC print is also very lightweight.
At our print house in Pune, we produce large posters using a wide-format inkjet printer. These printers reproduce images on giant rolls of flexible, printable vinyl media. However, vinyl prints lack rigidity and are essentially thin plastic rolls with a sticker backing.
You need an advertisement poster that is thick, ‘solid,’ and features a smooth, premium finish. To achieve this, we mount our loose vinyl roll onto a thick, rigid PVC sheet. This sheet, commonly known in industry as a low-density polystyrene board, provides the necessary strength and quality.
A foam board print is a sturdy plastic sheet with a smooth surface that allows for high-quality image printing. As a buyer, you should be aware of the different types of sun board prints offered by Orchid Digitals in Pune.
Video of Sunboard Printing Services at Orchid Digitals
Different Types of Sunboard Prints Available at Orchid Digitals
Different Types of Sunboard Prints Available at Orchid Digitals
We manufacture PVC sign boards in a vast range of thicknesses.
You can order sheets as thin as 3 mm or as thick as 25 mm. The construction and furniture industry goes a step further and works with 40 mm-thick PVC sheets. This sheet is a full inch and a half thick!
The print industry regularly uses sheets of 3, 5 mm thickness to manufacture images. But at Orchid Digitals, we can provide prints on sunboard sheets of 10, 15 and even 25 mm thickness!
You will mainly encounter sunboard prints in the print industry with a depth of either 3 mm or 5 mm. While the image reproduction on both these sheets is excellent, their use cases differ slightly.
We manufacture PVC sign boards in a vast range of thicknesses.
You can order sheets as thin as 3 mm or as thick as 25 mm. The construction and furniture industry goes a step further and works with 40 mm-thick PVC sheets. This sheet is a full inch and a half thick!
You will mainly encounter sunboard prints in the print industry with a depth of either 3 mm or 5 mm. While the image reproduction on both these sheets is excellent, their use cases differ slightly.
3 mm Thick Sunboard Prints
High-resolution print on 3 mm thick Sunboard + Top Coat of Protective Lamination
₹100 per sq foot + 18% GST
High-resolution print on 3 mm thick Sunboard (Without Lamination)
A print on a 3 mm thick sunboard is our most popular item. Besides being visually appealing, it is also very economical.
You can use a stud cap to mount it on the wall. Additionally, a 3 mm thick sunboard is so lightweight that you can attach it with double-sided tape to a wall or glass surface.
We recommend choosing a 3 mm thick print in situations where you can provide extra support. For instance, if you plan to drill the poster onto the wall, opt for a 3 mm thick PVC sheet to save money.
However, for prints that need more strength, you might prefer a thicker option.
5 mm Thick Sunboard Prints
High-resolution print on 5 mm thick Sunboard + Top Coat of Protective Lamination
₹130 per sq foot + 18% GST
High-resolution print on 5 mm thick Sunboard (Without Lamination)
A 3 mm thick print looks good because of its thickness (or thinness). However, the material lacks sufficient strength, so it cannot stand on its own. For example, if you place this sunboard print on an easel stand, it may not stand upright, or it may bend in the centre.
For example, if you place this sunboard print on an easel stand, it may not stand upright, or it may bend in the centre.
We offer sunboard prints that are 5 mm thick, which is a more premium option than 3 mm prints. Along with a classy appearance, this material is stronger. Moreover, a 5 mm-thick sunboard will not dent as easily as a 3 mm sheet.
The 5 mm sunboard is also required for smaller-sized prints. For example, if a 3 mm thick, handheld print (like a restaurant menu card) wilts, it will create a bad impression. In this case, using thicker and more rigid material makes sense.
While most of our competitors stop at 5 mm, Orchid Digitals offers prints on even 10 mm-thick PVC sheets.
10 mm and 15 mm Thick Sunboard Prints
High-resolution print on 10 mm thick WPC sheet + Top Coat of Protective Lamination
₹220 per sq foot + 18% GST
High-resolution print on 15 mm thick WPC sheet + Top Coat of Protective Lamination
10 mm & 15 mm Thick Sunboard Print Cost Calculator
While most of our competitors stop at 5 mm, Orchid Digitals offers prints on 10 mm, 15 mm, and even 25 mm thick WPC sheets. Apart from being thicker than the traditional PVC sheet prints, WPC sheets are also significantly more stronger and longer-lasting.
At Orchid Digitals, apart from sunboard, we also supply a strong material called WPC—Wood Plastic Composite.
WPC, as the name suggests, is a composite made of wood shavings and residual plastic pieces all glued together. The final result is an extremely durable piece of plastic, nearly as strong as wood. WPC is commonly used in the furniture and construction industries, but it can also be utilised for printing purposes.
Although WPC and Sunboard are in the same category, they differ significantly. Sunboard has a very low density because of trapped air bubbles, while WPC contains more tightly packed plastic material. As a result, WPC sheets are much denser and stronger than typical foam core boards used in printing.
When you need greater durability in your prints, such as a road direction sign that must withstand strong winds or an exhibition backdrop that needs to be self-supporting and stand firm without wilting, you should choose WPC prints.
Observe this exhibition backdrop, mounted vertically with a sturdy base support. These large prints need to stay upright and be strong enough to resist warping from their weight.
For such purposes, we are one of the few print providers that stock sunboard sheets in thicknesses of 10 mm, 15 mm, and even 25 mm.
Outdoor Grade, Weatherproof ACP — Aluminium Composite Panel Prints
High-resolution outdoor grade and weatherproof print on 3 mm thick ACP sheet + Top Coat of Protective Lamination
₹220 per sq foot + 18% GST
Aluminium Composite Panels, also known as ACP sheets, are a highly durable material primarily used in the construction and furniture industries. They are also utilised in the print industry for applications where the print needs to be exceptionally strong.
Outdoor Grade, Weatherproof ACP — Aluminium Composite Panel Prints
High-resolution outdoor grade and weatherproof print on 3 mm thick ACP sheet + Top Coat of Protective Lamination
₹220 per sq foot + 18% GST
Aluminium Composite Panels, also known as ACP sheets, are a highly durable material primarily used in the construction and furniture industries. They are also utilised in the print industry for applications where the print needs to be exceptionally strong.
Weatherproof prints come with a top coat of protective lamination by default.
Price is at ₹220/sq ft.
ACP sheets are made of two thin aluminium foils with a rubber sheet sandwiched in between.
This rubber core is thick, rigid, and highly dense, providing the ACP sheet with considerable strength.
This strength is useful when creating signs that must operate in extremely harsh conditions.
At Orchid Digitals, we produce road direction signs, safety signs, and factory shop-floor prints using aluminium composite panels. These ACP sheets do not rust or deteriorate over time.
With their durable metallic exterior, they are also quite resistant to dents.
Printed foam sheets are prone to cracks and breakage under pressure. However, an ACP sheet print can withstand even the harshest environments.
We also use a special outdoor-grade vinyl when manufacturing ACP prints. This vinyl is weatherproof and can endure the extreme temperatures of outdoor locations.
The print does not crack, peel, or fade when exposed to the elements like rain or sunlight.
Road signs have to be able to withstand exceptionally severe conditions. And so, we use high-grade cast vinyl mounted on aluminium composite sheets to create these signboards.
At Orchid Digitals, we also offer night reflective prints. This reflective vinyl has tiny prisms embedded on its front face. And these prisms act like mirrors, reflecting any light that hits them.
Night reflective media is ideal for displaying print communication in low-light conditions, such as on highways at night or in foggy areas.
Since these prints are typically installed outdoors on roads and highways, they are often mounted on aluminium composite panels. The result is a reflective ACP signage that remains highly visible during both day and night, and is also durable and resistant to harsh weather conditions.
Limitless possibilities & Endless applications
A foam core print is a highly adaptable marketing solution. Its advertising and communication uses are only limited by your imagination.
Besides standard photo posters, sunboard is used for standees, wall posters, cardboard cutouts, toys, exhibition display panels, wall prints, factory shop floor signs, safety signs, company name and address plates, logo sign boards, product photo prints, room door hangers, QR code stands, restaurant menu cards, easel stand prints, and more.
Below is a thorough (though not all-inclusive) list of common uses for foam sheet prints we encounter regularly.
Limitless possibilities & Endless applications of Foamsheet Prints
A foam core print is a highly adaptable marketing solution. Its advertising and communication uses are only limited by your imagination.
Besides standard photo posters, sunboard is used for standees, wall posters, cardboard cutouts, toys, exhibition display panels, wall prints, factory shop floor signs, safety signs, company name and address plates, logo sign boards, product photo prints, room door hangers, QR code stands, restaurant menu cards, easel stand prints, and more.
Below is a thorough (though not all-inclusive) list of common uses for foam sheet prints we encounter regularly.
Wall branding in modern trade stores and retail outlets
Every retail outlet, mall, and shop displays its products and promotions on posters affixed to walls, with foam board posters being the preferred material for this purpose.
The next time you see a large-scale image of a model promoting clothing, perfumes, electronics, etc., take a moment to check the material. You’ll notice that commercial spaces mainly use these inexpensive posters to boost brand and product awareness. Additionally, foam core posters are simple to remove and replace.
Wall branding in modern trade stores and retail outlets
Every retail outlet, mall, and shop displays its products and promotions on posters affixed to walls, with foam board posters being the preferred material for this purpose.
The next time you see a large-scale image of a model promoting clothing, perfumes, electronics, etc., take a moment to check the material.
You’ll notice that commercial spaces mainly use these inexpensive posters to boost brand and product awareness.
Additionally, foam core posters are simple to remove and replace.
While vinyl prints mounted on a sunboard offer a superb finish and are visually appealing, they are excellent for advertising. Because they are also very cost-effective, they help keep your advertising budget under control.
Low-cost display stands for point-of-sale marketing.
Foam sheet prints are quite rigid. The 5 mm thick version is particularly stiff, standing almost as firm as a wooden plank when positioned vertically. Besides this strength and rigidity, sunboard prints are also very lightweight due to their low density, making them easy to transport to various locations.
Using foam sheets offers a cost-effective alternative to wooden planks. Additionally, they can be printed with marketing messages to create freestanding, vertical posters. At Orchid Digitals, we also make flap stands and attach them behind the posters to support them, allowing the prints to stand independently.
Low-cost display stands for point-of-sale marketing.
Foam sheet prints are quite rigid. The 5 mm thick version is particularly stiff, standing almost as firm as a wooden plank when positioned vertically.
Besides this strength and rigidity, sunboard prints are also very lightweight due to their low density, making them easy to transport to various locations.
Using foam sheets offers a cost-effective alternative to wooden planks. Additionally, they can be printed with marketing messages to create freestanding, vertical posters.
At Orchid Digitals, we also make flap stands and attach them behind the posters to support them, allowing the prints to stand independently.
Sunboard standees are lightweight but sturdy enough to stand upright, making them an effective, low-cost advertising option for businesses. They are ideal for displaying product images or services at malls, supermarkets, and other point-of-sale locations.
Creating sunboard standees is a quick and straightforward process. Many campaigns involve ordering hundreds of these stands from us. Most importantly, they are very economical, so disposing of them after a campaign concludes won’t significantly impact your budget.
Exhibition Panels
An exhibition is a key venue where potential clients will constantly assess you and your products. Therefore, your marketing communication at trade shows must be effective. The posters displayed in trade fairs should be of a high quality and give off a professional look.
I have seen too many stalls in exhibitions use cheap flex banner prints to display their products and services. These banners invariably look creased, wrinkled and unprofessional.
High-resolution images printed on sunboard posters can give your business a very professional look and quickly establish trust with clients.
Exhibition Panels
An exhibition is a key venue where potential clients will constantly assess you and your products.
Therefore, your marketing communication at trade shows must be effective.
The posters displayed in trade fairs should be of a high quality and give off a professional look.
I have seen too many stalls in exhibitions use cheap flex banner prints to display their products and services. These banners invariably look creased, wrinkled and unprofessional.
High-resolution images printed on sunboard posters can give your business a very professional look and quickly establish trust with clients.
Exhibition octonorm stalls typically consist of sections that are 1 meter wide. Our sunboard prints can be easily mounted in these sections using double-sided tape. After the event, you can take the prints back to your office and repurpose them as wall posters.
While sunboard prints are rigid—which can make transporting them over long distances challenging—we offer an alternative for clients holding outdoor exhibitions outside Pune.
This alternative print can be rolled up and carried in a compact plastic container. To learn more about this solution, visit the product page for exhibition posters here.
Wheel Of Fortune Game
This personalised printed Wheel of Fortune game is sure to be a hit at any event or party.
The game features a rotating wheel at its centre, decorated with images of various prizes. A fixed arrow is positioned at one end, inviting players to spin the wheel and test their luck. When the wheel stops, the arrow points to the prize the player wins.
The stand is made from high-resolution print mounted on a sturdy, rigid PVC sheet, with the sunboard print installed on a metal frame.
Wheel Of Fortune Game
This personalised printed Wheel of Fortune game is sure to be a hit at any event or party.
The game features a rotating wheel at its centre, decorated with images of various prizes. A fixed arrow is positioned at one end, inviting players to spin the wheel and test their luck. When the wheel stops, the arrow points to the prize the player wins.
The stand is made from high-resolution print mounted on a sturdy, rigid PVC sheet, with the sunboard print installed on a metal frame.
We also include a bearing in the assembly to ensure the disc spins smoothly. The final product is a printed item that also functions as an entertaining party game- sure to brighten your celebration and bring smiles to all your guests.
Shape Cut Standees / Life-size Cutouts
As mentioned earlier, a foam sheet is simply a PVC print on a plastic sheet. While this sheet is lightweight and rigid, it is also quite easy to cut into any shape you want. This feature enables a very interesting application: life-sized cardboard cutouts!
At Orchid Digitals, we have large laser-cutting and CNC routing machines. These CNC machines can cut a rectangular piece of printed foam core board into any non-linear shape. They are ready to handle such jobs.
Shape Cut Standees / Life-size Cutouts
As mentioned earlier, a foam sheet is simply a PVC print on a plastic sheet.
While this sheet is lightweight and rigid, it is also quite easy to cut into any shape you want. This feature enables a very interesting application: life-sized cardboard cutouts!
At Orchid Digitals, we have large laser-cutting and CNC routing machines. These CNC machines can cut a rectangular piece of printed foam core board into any non-linear shape. They are ready to handle such jobs.
Want a cutout in the shape of a cartoon? No problem. Looking for a print cut in the shape of an action figure or even a celebrity? We can do that!
Want a cutout in the shape of a cartoon? No problem. Looking for a print cut in the shape of an action figure or even a celebrity? We can do that!
A cutout standee is an excellent way to attract customer attention in a retail store or to create a fun selfie booth at events or parties. We can cut sunboard prints into shapes of products, mascots, logos, life-sized models, and of course, celebrities.
Rigid menu cards made of foam sheet are a premium and durable alternative to traditional paper menus in restaurants. This type of menu is quite popular in fast food and casual dining establishments.
A print with some heft looks much more luxurious than a standard paper menu. Such a menu also positively reflects on the brand or restaurant.
A menu card printed on foam core has a very long lifespan. Since it is made of plastic, there is no risk of water damage. The lamination film on top protects the printed images from oil smudges. Additionally, a sunboard menu will never get dog-eared like traditional paper menus.
Menu Cards for Restaurants
Rigid menu cards made of foam sheet are a premium and durable alternative to traditional paper menus in restaurants.
This type of menu is quite popular in fast food and casual dining establishments.
A print with some heft looks much more luxurious than a standard paper menu. Such a menu also positively reflects on the brand or restaurant.
A menu card printed on foam core has a very long lifespan. Since it is made of plastic, there is no risk of water damage. The lamination film on top protects the printed images from oil smudges.
Additionally, a sunboard menu will never get dog-eared like traditional paper menus.
A menu card printed on foam core has a very long lifespan. Since it is made of plastic, there is no risk of water damage. The lamination film on top protects the printed images from oil smudges. Additionally, a sunboard menu will never get dog-eared like traditional paper menus.
Pasting a loose sheet of printed paper on a wall looks exceptionally tacky. Alternatively, a flat and smooth sheet of printed sunboard will add a touch of class to your communication.
High-quality posters are the main application of this material. Also, you can create giant-sized posters by printing on a PVC sheet. We process two by three feet and 3 X 4 feet as the most standard sizes. But a poster of eight and even ten feet is not unheard of, and can easily be provided.
Wall posters for offices and commercial spaces
Pasting a loose sheet of printed paper on a wall looks exceptionally tacky.
Alternatively, a flat and smooth sheet of printed sunboard will add a touch of class to your communication.
High-quality posters are the main application of this material. Also, you can create giant-sized posters by printing on a PVC sheet.
We process two by three feet and 3 X 4 feet as the most standard sizes. But a poster of eight and even ten feet is not unheard of, and can easily be provided.
Home interior applications such as personalised furniture panels, paintings, and photos
You can use sunboard prints to create some pretty unique furniture decor.
Here’s an example where images of two children are reproduced at very high resolution and in vibrant colours on foam core sheets. These photo prints are then mounted or fixed on the front panel of a wardrobe or cupboard.
Suddenly, a boring cupboard becomes very interesting and eye-catching. Notably, while such foam prints are inexpensive, this unique application can significantly upgrade the look of your home interiors.
Home interior applications
You can use sunboard prints to create some pretty unique furniture decor.
Here’s an example where images of two children are reproduced at very high resolution and in vibrant colours on foam core sheets.
These photo prints are then mounted or fixed on the front panel of a wardrobe or cupboard.
Suddenly, a boring cupboard becomes very interesting and eye-catching. Notably, while such foam prints are inexpensive, this unique application can significantly upgrade the look of your home interiors.
An Instagram frame is designed to replicate the familiar interface of the popular social media app, making it a fun accessory for events and gatherings. This unique frame is created by printing a high-quality image that highlights your Instagram username and features your profile picture prominently.
To enhance the interactive experience, we also cut out a section in the centre, forming a designated area for guests to pose and take selfies.
For added convenience, we’ve incorporated sturdy handholds on the back of the frame, ensuring ease of handling while taking photos. This thoughtful design enables anyone to capture selfies and photo moments effortlessly.
So, whether you’re hosting a birthday party, wedding, or promotional event, you’ll have a vibrant Instagram Selfie Booth ready for use, allowing guests to engage with your brand or personal account in a lively and memorable way!
Instagram Frames
An Instagram frame is designed to replicate the familiar interface of the popular social media app, making it a fun accessory for events and gatherings.
This unique frame is created by printing a high-quality image that highlights your Instagram username and features your profile picture prominently.
To enhance the interactive experience, we also cut out a section in the centre, forming a designated area for guests to pose and take selfies.
For added convenience, we’ve incorporated sturdy handholds on the back of the frame, ensuring ease of handling while taking photos. This thoughtful design enables anyone to capture selfies and photo moments effortlessly.
So, whether you’re hosting a birthday party, wedding, or promotional event, you’ll have a vibrant Instagram Selfie Booth ready for use, allowing guests to engage with your brand or personal account in a lively and memorable way!
Sunboard prints offer remarkable versatility, allowing them to be moulded and cut into a wide range of shapes for various applications.
A prime example of a small-sized, non-linear sunboard print is the door hanger commonly used in hotels. To create this item, we print the messaging “Do Not Disturb” on one side and “Clean My Room” on the opposite side of a foam sheet. This dual-sided printing ensures that hotel guests can easily communicate their preferences to hotel staff.
Once printed, the rectangular foam sheet is placed into a CNC (Computer Numerical Control) machine, which precisely cuts it into the desired dangler shape. This customised design allows the door hanger to be easily hung from the handle of a hotel room door, ensuring visibility and practicality.
The result is a functional and aesthetically appealing door hanger that enhances the overall guest experience in hotels.
Door Hangers & Danglers
Sunboard prints offer remarkable versatility, allowing them to be moulded and cut into a wide range of shapes for various applications.
A prime example of a small-sized, non-linear sunboard print is the door hanger commonly used in hotels. To create this item, we print the messaging “Do Not Disturb” on one side and “Clean My Room” on the opposite side of a foam sheet. This dual-sided printing ensures that hotel guests can easily communicate their preferences to hotel staff.
Once printed, the rectangular foam sheet is placed into a CNC (Computer Numerical Control) machine, which precisely cuts it into the desired dangler shape. This customised design allows the door hanger to be easily hung from the handle of a hotel room door, ensuring visibility and practicality.
The result is a functional and aesthetically appealing door hanger that enhances the overall guest experience in hotels.
Photoluminescent or glow-in-the-dark safety signs are crucial for enhancing safety, particularly in emergencies in factories and industrial shop floors.
At Orchid Digitals, we offer night glow prints that absorb light during the day and emit it in low light conditions, making them visible even without electrical power.
These signs are essential in emergency scenarios, like fires, where electrical-powered signs may fail. They guide people to safety, even in complete darkness, by glowing like a beacon.
OSHA (Occupational Safety And Health Administration) mandates that all emergency and fire safety signs be made from night glow materials.
Orchid Digitals uses high-quality UV inks and reliable night glow media from reputable brands like Avery Dennison™ and 3M™ to ensure durability and effectiveness. This night glow media is mounted on a sunboard sheet, converting it into a thick, rigid signboard that can be easily fixed to the walls inside your organisation.
Safety Signs For Factories & Shop Floors
Photoluminescent or glow-in-the-dark safety signs are crucial for enhancing safety, particularly in emergencies in factories and industrial shop floors.
At Orchid Digitals, we offer night glow prints that absorb light during the day and emit it in low light conditions, making them visible even without electrical power.
These signs are essential in emergency scenarios, like fires, where electrical-powered signs may fail. They guide people to safety, even in complete darkness, by glowing like a beacon.
OSHA (Occupational Safety And Health Administration) mandates that all emergency and fire safety signs be made from night glow materials.
Orchid Digitals uses high-quality UV inks and reliable night glow media from reputable brands like Avery Dennison™ and 3M™ to ensure durability and effectiveness
This night glow media is mounted on a sunboard sheet, converting it into a thick, rigid signboard that can be easily fixed to the walls inside your organisation.
Sunboard sheets are thick. Plastic, as we all know, can also be molded into very smooth and flat sheets. And manufacturers supply sunboard sheets in a variety of thicknesses ranging from one mm to a full inch.
The print industry regularly uses sheets of 3, 5 mm thickness to manufacture images. But at Orchid Digitals, we can provide prints on sunboard sheets of 10, 15, and even 25 mm consistency
rigid foamsheet printing used in the sign industry to create posters
Vinyl Sunboards Are Thick
Sunboard sheets are thick. Plastic, as we all know, can also be molded into very smooth and flat sheets.
And manufacturers supply sunboard sheets in a variety of thicknesses ranging from one mm to a full inch.
The print industry regularly uses sheets of 3, 5 mm thickness to manufacture images. But at Orchid Digitals, we can provide prints on sunboard sheets of 10, 15, and even 25 mm consistency
A sunboard sheet is exceptionally light in weight. So much so that you can easily carry a sizeable, 8-foot print under your arms.
A large part of the foam sheet is nothing but bubbles of air trapped between loosely packed molecules of plastic. This is why the foam sheets are lightweight as feathers. This bubble analogy is probably also why sunboard sheets are colloquially known as foam sheets here in Pune city.
Foam Board Posters Are Lightweight
A sunboard sheet is exceptionally light in weight. So much so that you can easily carry a sizeable, 8-foot print under your arms.
A large part of the foam sheet is nothing but bubbles of air trapped between loosely packed molecules of plastic. This is why the foam sheets are lightweight as feathers.
This bubble analogy is probably also why sunboard sheets are colloquially known as foam sheets here in Pune city.
In addition to being lightweight, sunboard prints are also pretty rigid. And when I say ‘rigid’ think wooden, plank-like stiffness. Polystyrene is also a pretty strong material. This is necessary because otherwise, a large-sized print is liable to wilt under its own weight.
A PVC Sign Board Has Strength & Rigidity
In addition to being lightweight, sunboard prints are also pretty rigid. And when I say ‘rigid’ think wooden, plank-like stiffness.
Polystyrene is also a pretty strong material.
This is necessary because otherwise, a large-sized print is liable to wilt under its own weight.
Finally, sunboard sheets have a very smooth surface. This enables printers to reproduce high-resolution images on the same. Print houses mainly use the following two methods to create foamsheet prints:
Paste a vinyl sheet on top
Most print-houses print your job on a roll of vinyl. This vinyl print is then pasted on top of a blank sheet of sunboard to create the final product. Printers use a specialised hydraulic pressing machine to fuse the vinyl print and its base foamsheet.
The end result is a very evenly finished, smooth looking job.
Use a flatbed UV printer to print on the foamsheet directly
Some print houses deploy specialised flatbed printing machines. These machines print directly onto the sunboard sheet and cut out the vinyl ‘middleman’.
While this technology cuts one step from the production process, it is still at a nascent stage and has yet to be widely adopted. In case you are curious to learn more, we have a detailed post about UV flatbed printing here.
Printed Foam Sheets Have A Smooth Surface
Finally, sunboard sheets have a very smooth surface. This enables printers to reproduce high-resolution images on the same.
Print houses mainly use the following two methods to create foamsheet prints:
Paste a vinyl sheet on top
Most print-houses print your job on a roll of vinyl. This vinyl print is then pasted on top of a blank sheet of sunboard to create the final product. Printers use a specialised hydraulic pressing machine to fuse the vinyl print and its base foamsheet.
The end result is a very evenly finished, smooth looking job.
Use a flatbed UV printer to print on the foamsheet directly
Some print houses deploy specialised flatbed printing machines. These machines print directly onto the sunboard sheet and cut out the vinyl ‘middleman’.
While this technology cuts one step from the production process, it is still at a nascent stage and has yet to be widely adopted. In case you are curious to learn more, we have a detailed post about UV flatbed printing here.
The surface of a foam sheet print is smooth, coated, and has an even finish. Once a high-resolution vinyl print is pasted onto this sheet, the end result is extremely beautiful and appealing to look at.
These good looks are the reason advertising agencies go for vinyl sun boards without a second thought. Almost all the posters you see in supermarkets, malls, and retail stores are this material.
They Look Terrific!
The surface of a foam sheet print is smooth, coated, and has an even finish.
Once a high-resolution vinyl print is pasted onto this sheet, the end result is extremely beautiful and appealing to look at.
These good looks are the reason advertising agencies go for vinyl sun boards without a second thought.
Almost all the posters you see in supermarkets, malls, and retail stores are this material.
Vinyl Sunboard Prints Are Easy to Handle and Lightweight
Foam sheets are incredibly lightweight. Even large-sized posters of 10 feet are easy to handle and can be easily carried by just a single person.
This lightweight yet strong material then becomes very versatile and fulfills multiple applications. At Orchid Digitals, we use this material for wall posters, inside acrylic frames, for making display stands, life-size cutouts, and even handheld menu cards.
We cover the various applications of sunboard prints in this section here.
Vinyl Sunboard Prints Are Easy to Handle and Lightweight
Foam sheets are incredibly lightweight. Even large-sized posters of 10 feet are easy to handle and can be easily carried by just a single person.
This lightweight yet strong material then becomes very versatile and fulfills multiple applications. At Orchid Digitals, we use this material for wall posters, inside acrylic frames, for making display stands, life-size cutouts, and even handheld menu cards.
We cover the various applications of sunboard prints in this section here.
By virtue of being strong and very light in weight, sunboard prints can be easily installed. You can mount these prints on the wall with just a couple of nails or even two-sided tape.
This convenience for installation makes PVC prints relatively easy to deploy at end-point locations. We talk more about how to install these prints in this section here.
Sunboard Prints Are Easy to Install
The foam sheet prints produced at Orchid Digitals have a top coat of lamination.
Laminated prints have a significantly longer life than their non-laminated counterparts.
They are waterproof and scratch-resistant. A layer of lamination film pasted on the image also prevents the inks from fading in the sunlight.
The process of making a Sunboard poster consists of 2 categories:
Components
Production process
If you are interested in the process of production you can watch our videos on Sunboard production.
Individual Material Components of a Sunboard Print
Vinyl
We print our image on a material called Vinyl. Printable Vinyl comes in a roll form. These rolls are 3 or 4 or 5 feet wide, very much like rolls of cloth. These rolls are hundreds of feet in length. So this means that you can have a print 5 feet wide and long as much as 20 or 30 feet in length.
Vinyl has two surfaces. The top surface allows the reproduction of extremely high-resolution images. In the olden days, we had silver halide films on which, if we expose a photographic light then a high-quality image will reproduce. Vinyl is specially coated to receive ink.
Vinyl
We print our image on a material called Vinyl. Printable Vinyl comes in a roll form. These rolls are 3 or 4 or 5 feet wide, very much like rolls of cloth.
These rolls are hundreds of feet in length. So this means that you can have a print 5 feet wide and long as much as 20 or 30 feet in length.
Vinyl has two surfaces. The top surface allows the reproduction of extremely high-resolution images. In the olden days, we had silver halide films on which, if we expose a photographic light then a high-quality image will reproduce. Vinyl is specially coated to receive ink.
The lower surface of the vinyl has a got glue or adhesive under it. So it is easy to paste a vinyl print on top of a sunboard. We will talk about this process in the production process. You can also read our blog on vinyl for more information.
Disclaimer: If you want a Vinyl printed sunboard most of the printers will suggest a presentation Vinyl. The presentation looks good, but at Orchid Digitals we stock extremely high weather Vinyl that can withstand the service temperature of -45 degrees Celsius to +95 degrees Celsius. We are official converters for an American company 3M, Oracle, and some top brands in the field. If you want to install prints on highways, deserts, or in extreme weather conditions drop us a mail.
Lamination coat
Lamination coat is more like a protective layer of plastic on top of a vinyl print. The purpose of this lamination is to protect the vinyl print from degradation. Let us have a look at how lamination can add more life to your sunboard prints
Protection from scratches: If you have a Sunboard print on a wall and people or various things brush the Sunboard on its way then it can cause a scratch. A lamination can reduce these scratch marks drastically.
Protects from daily wear and tear: If you have a sunboard print at your home while cleaning the print if you wipe it daily then there is a possibility of vinyl print may lose its colors from water damage.
Lamination coat.
Lamination coat is more like a protective layer of plastic on top of a vinyl print. The purpose of this lamination is to protect the vinyl print from degradation.
Let us have a look at how lamination can add more life to your sunboard prints
Vinyl has two surfaces. The top surface allows the reproduction of extremely high-resolution images. In the olden days, we had silver halide films on which, if we expose a photographic light then a high-quality image will reproduce. Vinyl is specially coated to receive ink.
Protection from scratches: If you have a Sunboard print on a wall and people or various things brush the Sunboard on its way then it can cause a scratch. A lamination can reduce these scratch marks drastically.
Protects from daily wear and tear: If you have a sunboard print at your home while cleaning the print if you wipe it daily then there is a possibility of vinyl print may lose its colors from water damage.
Disclaimer: Generally colors dissolve over a period of time. But at Orchid Digitals we use original colors for ink. We take pride in saying that our inks are of high-quality grade and insoluble in water. Even if you do not add lamination water cannot damage the ink. However, an additional layer of lamination will always help.
The base i.e., the Sunboard
The lowermost base is the Sunboard which can be a 3 mm sheet, or 5 mm sheet, or even a 10 mm sheet. Know more about the varieties of the Sunboard and which one is best for you.
The base i.e., the Sunboard
The lowermost base is the Sunboard which can be a 3 mm sheet, or 5 mm sheet, or even a 10 mm sheet. Know more about the varieties of the Sunboard and which one is best for you.
All Vinyl prints are manufactured on large wide format machines.
At Orchid Digitals we have some highest-end machinery that is capable of reproducing images at mind-blowing resolutions.
This machine is known as a roll-to-roll printer. It is pretty much the same as your printer or desktop.
A roll of Vinyl is loaded at the backside of the machine, the vinyl print is unspoiled on the printer bed. The heads of the printer run on the Vinyl sheet and outcome the image of the finished product.
The next step is to bring all the components together. At Orchid Digitals we have the pneumatic press. On the Pneumatic machine, we fuse the lamination roll on the top, and then we fuse the vinyl print to the base sheet of the respective Sunboard (3 mm, 5 mm, etc.). This was all about the production process in brief.
All Vinyl prints are manufactured on large wide format machines. At Orchid Digitals we have some highest-end machinery that is capable of reproducing images at mind-blowing resolutions.
This machine is known as a roll-to-roll printer. It is pretty much the same as your printer or desktop.
A roll of Vinyl is loaded at the backside of the machine, the vinyl print is unspoiled on the printer bed. The heads of the printer run on the Vinyl sheet and outcome the image of the finished product.
The next step is to bring all the components together. At Orchid Digitals we have the pneumatic press. On the Pneumatic machine, we fuse the lamination roll on the top, and then we fuse the vinyl print to the base sheet of the respective Sunboard (3 mm, 5 mm, etc.). This was all about the production process in brief.
Simple and easy ways to install foam board Sunboards
Sunboard prints are extremely light in weight. So fixing them on walls is pretty easy. Here are some options to install your posters at home or in the office.
Stick the Print Using Two-sided tape
The easiest and most hassle-free method to fix your sunboard print on the wall is to use two-sided tape. You don’t need any special tools or equipment to do the job. You do not even need to buy the tape! Just instruct us, and we will do what is necessary.
When you commission your foam sheet print from us, we can provide the two-sided tape on its edges for you. Our tape also has very strong adhesion that will prevent the print from falling off.
What remains is for you to peel the tape and paste the print at your end.
Stick the Print Using Two-sided tape
The easiest and most hassle-free method to fix your sunboard print on the wall is to use two-sided tape.
You don’t need any special tools or equipment to do the job. You do not even need to buy the tape! Just instruct us, and we will do what is necessary.
When you commission your foam sheet print from us, we can provide the two-sided tape on its edges for you. Our tape also has very strong adhesion that will prevent the print from falling off.
What remains is for you to peel the tape and paste the print at your end.
Two-sided tape works great for prints up to 2 feet X 3 feet in size. But larger posters are heavier and will require additional support.
For bigger (and heavier) prints, we recommend that you nail the same to the wall. This will ensure that the foam board does not fall off. Since our material is pretty light, thin wire nails will do the trick. You need not deploy large-sized screws, which can otherwise deface the wall.
If you do use big-size screws to fix the print, consider placing a mirror cap on top, to mask the screw head. This will make your installation look very neat and tidy.
Nail the Print to the Wall
Two-sided tape works great for prints up to 2 feet X 3 feet in size. But larger posters are heavier and will require additional support.
For bigger (and heavier) prints, we recommend that you nail the same to the wall. This will ensure that the foam board does not fall off. Since our material is pretty light, thin wire nails will do the trick. You need not deploy large-sized screws, which can otherwise deface the wall.
If you do use big-size screws to fix the print, consider placing a mirror cap on top, to mask the screw head. This will make your installation look very neat and tidy.
One excellent way of installing sunboard posters is to use risers along with a shiny stud or mirror cap on top.
A riser is a hollow steel cylinder that goes behind the print. Its function is to increase the gap between the sunboard and the wall. In effect, a ‘riser’ raises the print away from the wall to give it a 3D-like effect.
So, you first place a riser beneath the print. You then insert a screw through both, the print on top and the riser beneath. This screw is also drilled into the wall to hold everything in place.
Finally, a stud or mirror cap is placed on top of the screw head to mask it. A stud-cap is a round metallic disk that neatly covers the screw head on the front of the print. The overall effect, once the poster is fixed, looks very premium and classy.
Use Stud Caps and Risers
One excellent way of installing sunboard posters is to use risers along with a shiny stud or mirror cap on top.
A riser is a hollow steel cylinder that goes behind the print. Its function is to increase the gap between the sunboard and the wall. In effect, a ‘riser’ raises the print away from the wall to give it a 3D-like effect.
If you do use big-size screws to fix the print, consider placing a mirror cap on top, to mask the screw head. This will make your installation look very neat and tidy.
So, you first place a riser beneath the print. You then insert a screw through both, the print on top and the riser beneath. This screw is also drilled into the wall to hold everything in place.
Finally, a stud or mirror cap is placed on top of the screw head to mask it. A stud-cap is a round metallic disk that neatly covers the screw head on the front of the print. The overall effect, once the poster is fixed, looks very premium and classy.
A lot of our first-time customers come to us with the following intention:
Get paper or vinyl posters printed at our end
Frame the above at another frame shop (since we don’t provide framing service)
We offer sunboard with vinyl as an alternative to the traditional wooden frames. I believe that the former is a better and more economical alternative to the latter. A vinyl sunboard print is a complete, standalone product. You can directly drill or paste them onto walls, as described in the previous paragraphs.
These prints will still look great sans any framing.
Frame Your Foam Sheet Prints at A Reduced Cost
A lot of our first-time customers come to us with the following intention:
* Get paper or vinyl posters printed at our end
* Frame the above at another frame shop (since we don’t provide framing service)
We offer sunboard with vinyl as an alternative to the traditional wooden frames. I believe that the former is a better and more economical alternative to the latter. A vinyl sunboard print is a complete, standalone product. You can directly drill or paste them onto walls, as described in the previous paragraphs.
These prints will still look great sans any framing.
But some of our customers still prefer to get their prints framed in wood. This is especially the case when the image has to be installed in a home as against an office environment.
So, in this case, I recommend that you only partially frame your sunboard print. This is way more economical than commissioning an entire frame, complete with a glass top and wooden base.
Here is what I mean:
You do not need to spend for the base of the frame
Frame shops will install a base of wood or MDF beneath your loose print to make the same stiff and rigid.
But our 5 mm / 10 mm thick sunboard print already acts as a solid and rigid base. There is no need to purchase an additional wooden base from the frame shop to ‘solidify’ the print. Do away with this base sheet of MDF and save your money.
The glass sheet on top is not required, either
Traditional frames have a protective sheet of glass on top of the print.
But, as I mentioned earlier, at Orchid Digitals, we paste a protective Matt/gloss film on top of the printed image. This lamination film makes the poster waterproof and scratch-resistant. You now no longer need the panel of glass provided by the frame shop.
Sunboard printing helps you opt-out of both the base beneath and the sheet of glass on top. All you need to spring for is the surrounding frame, or the ‘chaukat’, as we call it in Hindi.
reflective vinyl prints which shine brightly at night
FAQs | Frequently Asked Questions
I am confused. What kind of sunboard print do I choose?
Go for the entry level 3mm thick sunboard if the print has to be pasted on the wall. The 3mm material is not very sturdy but that should not really matter since the job is going to be drilled onto the wall anyways.
For prints that need to stand up on their own (without support) or for prints that have to be placed on very rough walls, I would recommend a 5mm thick sheet of sunboard. You will get a better finish.
For outdoor applications like road direction signs, building signs, etc., always opt for the ACP – Aluminium Composite Panel. Also be sure to inquire about our extreme-weather, vinyl prints. When pasted on ACP, this combo is almost indestructible.
The ACP will not rust and the all weather prints will not fade in the rains or under harsh sunlight.
One important point for you to note is that irrespective of the base thickness, the print on top will be of the same type, i.e. of an extremely high resolution.
How do I install my foam sheet print?
We have a pretty exhaustive section that lists a variety of different methods to install your job. Do check the installation section in the page above.
How do I decide if I need to laminate my print or not?
Laminating a print increases the cost of the same marginally. But it makes a huge difference in the life of the print. The top coat of lamination adds a protective layer to the image beneath. This protects the print from scratches dust and the wear and tear of everyday use.
Having said this, if the print does not need to last for long, or is going to be updated frequently, feel free to skip the lamination process and save your money.
What file format do I need to share while placing the order?
We can work with a variety of file formats. Do share your job as a .jpg, .pdf, .png, Corel Draw for EPS file.
Also, do make sure that the file has a sufficiently high resolution. While our machines have the capability to reproduce images of stunning quality, a high input resolution of your file will make a difference.
What is your MOQ – Minimum Order Quantity
The minimum size of print we can process is 3 feet X 4 feet. For sizes smaller than this the billing amount still remains the same as that of size 3 feet X 4 feet.
One print can off course contain multiple copies of smaller artworks.
How much time does it take for you to process the job?
We are pretty fast! And most jobs are processed in 1-2 days (not counting weekends and holidays). You also need to budget for extra time if the material is being couriered to you.
An estimated date of arrival will be conveyed to you once we mail across the Estimate (see next point).
How do I make payments?
Here is the process we follow:
Step 1. Mail us your job Step 2. We gather all the details necessary to execute the same Step 3. We then send you a Estimate / Proforma Invoice with costs and specifications Step 4: The estmate will also contain a QR code. All you need to do is scan the same for making the payments Step 5: Once the payments get credited to our account, we start of the job Step 6: If we are shipping the material to you, you will get a seperate email containing the Tracking Number / ID for tracking the delivery of the goods
Can I order multiple designs/artworks in your MOQ?
Yes. You can lay out multiple different designs or artworks in one print. As long as it matches our MOQ (Minimum Order Quantity) we will be fine with processing the job.
Do you offer on-site installation services for this product
We can send across a team for installing this product for our clients in Pune. This service will cost extra.
Shipping
Shipping for this product is limited to Pune and nearby areas. For larger quantities we can pack the same in a crate and ship the job across India.
Sunboard Printing Price
At Orchid Digitals, we provide prints on foam boards of 3 mm and 5 mm thickness. You can also choose to have these prints laminated. Here are the costs for all the options.
Print on silver metallic foil with matt / gloss finish. Ideal for interiors.
High resolution photo print
On metallic silver foil
Choice of matt / gloss top coat
Mounted on 5mm thick sunboard sheet
lightweight, and rigid panel
Ideal for images having metallic tints, chromium finish, gold / silver ornaments, etc. Metallic finish adds an additional dimension to your print to give it a premium look & feel.
Example Costing: ₹ 2400.00 for a print of 4 feet width X 3 feet height*
Print on silver metallic foil with sparkle / glitter top coat. Ideal for interiors.
High-resolution photo print
On metallic silver foil
Top coat of sparkle / glitter film
Mounted on 5mm thick sunboard sheet
lightweight, and rigid panel
Ideal for images having metallic tints, chromium finish, gold / silver ornaments, etc. Metallic finish adds an additional dimension to your print to give it a premium look & feel.
Example Costing: ₹2880.00 for a print of 4 feet width X 3 feet height*
This means you first need to work out the total area of your job to arrive at the final cost.
For example, let us assume that you require two sunboard prints of 3 mm thickness, without lamination. Further, these prints have a width of 3 feet and a height of 2 feet. In this case, the total cost of the job is calculated as follows…
3 feet width X 2 feet height X 2 copies X Rs.80.00 (cost of print, as per the table above)
= Rs.960.00 + 18% GST
Shipping and Delivery
Sunboard prints can be delivered anywhere in Pune City and its nearby areas. We also ship bulk quantities for longer distances.
Delivery charges are extra and will be communicated to you once we receive the delivery address.
Question: Does this product get shipped out of Pune City? Answer: We do not ship small quantities of this product outstation. Apologies.
Here are a couple of reasons for the same:
Hassle and Risk in Transportation: Sunboard is liable to break in transit. Also, these structures are pretty large and bulky. We need to hire a tempo to deliver them.
Economic Feasibility of Transportation: These boards are a pretty low-cost product. So, packing and shipping them over long distances means that our customers will pay more for the cost of delivery than the actual print cost.
Therefore, if you are stationed out of Pune and need just a few images, it makes sense for you to source the print from your local printer. All you have to do is share/take a print of the above post, show your local printer the material specifications and commission a similar job from him.
For larger quantities, do not hesitate to get in touch with us.
Get a Quote for Customized Sunboard Prints
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