How to Design an Oversize Custom Foam Prop

In theater, performance or dance, production sometimes calls for a very large prop. When these props need to be handled by performers and/or moved quickly offstage by stagehands, a lightweight design is essential. This makes Foam a fantastic choice for oversize props.

With a lightweight material that creates easy mobility but retains a rigid shape, foam is perfect for both backdrop and carried parts. As experts in foam prop creation, our Foam Party Decor team knows the design process from front to back. So, keep reading to learn what counts as an oversized foam prop, discover the benefits of extra-large theater props, and explore the best design tips to get started.

Note: This blog focuses on oversize props in a theater setting, but these can be used for parties, company events, and tradeshows as well! The same benefits and tips below apply no matter what event you’re using the part. 

How Big is “Oversize”?

For all intents and purposes, we’re counting any foam prop over 8 feet to be “oversized.” But just how big can these foam theater props get? Here at Foam Party Decor, the sky’s the limit. 

However, we’d recommend keeping it within the size constraints of your stage or splitting your oversized theater prop into multiple pieces to ensure it fits through the entrance (more on that later!).

Benefits of Foam for Oversize Props

Oversized foam props unlock a world of options in the theater world. Their easy customization and lightweight features are just the beginning of an endless amount of opportunities. Here are some of the biggest benefits you can experience by using oversized foam theater props:

• Ultra lightweight
• Extra durable
• Highly customizable
• More affordable
• Easier transportation
• Safer option
• Enhanced visibility

With the advantages of giant foam props in the front of your mind, you might be wondering just how to design an oversized custom foam prop. Keep reading, and we’ll give you some tips to get started below.

Related Blog: What is the Best Lightweight Material for Props?

Planning Your Foam Props

First things first, you need to decide what you’re making and what your project’s end result will look like. It helps to draw a picture of what you want or gather inspiration for your vision. Some common examples include: 

• Foam car on wheels
• Giant foam moon
• Foam castle
• Foam foliage
• Large foam characters (like dragons, horses, or giants)
• Foam boat or ship
• Foam trees

Once you have your design in mind, it’s time to actually put pen to paper (metaphorically or literally speaking). Keep these tips in mind:

• Consider how the prop will be used – Is it going to be stationary for the entire show? Will it be in the background but need to be moved? Will it be carried by the performers? Depending on the application, you’ll need to account for that in your design. For example, if the prop needs to be held by actors, you may need to design hidden hand holes so it can be carried.

• Will supports be needed? – Let’s go back to our examples above and to the dragon - the shape of this creature includes a small, narrow neck holding up a larger head. If this was all one continuous part, there’s a good chance that the neck might bend or snap under the weight. In that case, the prop should be designed as multiple pieces that are fitted together with hidden supports, to ensure there’s no damage.

• Work with an expert – To ensure your prop will perform how you want, partner with an expert. Foam Party Decor has extensive experience creating oversize props and can offer design advice and feedback to ensure your prop is optimally designed. 

Go Big and Go Foam 

If you’re ready to go big and invest in durable, lightweight foam for your theatrical production, our team at Foam Party Decor has just the tools you need to bring your vision to life. With our high-quality machines and various finishes, we can design virtually anything you need.

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Foam Party Decor is based in Rogers, Minnesota and we prioritize local pickup. If you need an item shipped to you, that will be an additional cost.

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Foam Party Decor is dedicated to awing and delighting every crowd with precision-made foam decor for all of life’s celebrated occasions and theatrical moments. We create bespoke foam decor and props. We are owned by Foam Industries, a nationally-recognized custom protective packaging company specializing in foam.