When it comes to large format signage, the choice of plastic substrate matters. The right material can enhance print clarity, improve durability, and streamline installation. While there are a variety of plastics on the market, some materials consistently rise to the top for wide-format printing—particularly Expanded PVC, Polystyrene, and Corrugated Plastic.
Below is a breakdown of commonly used plastics and where each one performs best based on industry use cases.
Expanded PVC (Sintra®, Komapure®): Durable, Professional, and Versatile
Expanded PVC—often referred to by brand names like Sintra® or Komapure®—is a rigid, closed-cell foam board. It’s frequently used in signage due to its balance of durability, weight, and print performance.
Why it’s commonly chosen:
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Provides a smooth, matte surface that supports sharp, vibrant prints
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Suitable for indoor and outdoor use in many environmental conditions
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Available in a variety of thicknesses and colors to suit multiple applications
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Can be routed, drilled, and heat bent for customized display options
Expanded PVC is often used for menu boards, wall graphics, tradeshow displays, retail signage, and construction site signs.
Polystyrene (Styrene): Lightweight, Affordable, and Flexible
Polystyrene (or styrene) is a cost-effective material widely used for indoor, short-term signage. It’s thinner and more flexible than PVC, which makes it easy to handle and ideal for volume-driven print projects.
Key features:
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Compatible with various printing methods for clear, crisp image quality
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Flexible and lightweight for hanging or framing
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Well-suited for custom die-cutting and temporary point-of-sale signage
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Comes in different opacities
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Can be easily customized to your needs, custom colors and sizes
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Special UV inhibitors and rubber modifiers can be added
Two common uses include:
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Translites – best for short term back lit displays
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Case Dividers – heat bendable and easily cleaned
Coroplast® (Corrugated Plastic): Lightweight, Weather-Resistant, and Reusable
Coroplast is a fluted polypropylene material often used for outdoor signage. Known for its lightweight construction and water resistance, it’s a practical solution for temporary and reusable signs.
Widely used for:
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Yard signs, event signage, and real estate signs
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Construction site wayfinding or safety signs
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Political campaigns and parking lot displays
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Bollard and pallet wraps
Its corrugated design adds rigidity while remaining easy to cut or mount using stakes.
Quick Comparison Table
Final Thoughts
The best plastic for your printing project depends on the environment, use duration, and overall aesthetic goals:
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Choose Expanded PVC for high-quality, long-lasting signage.
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Use Polystyrene for short-term or budget-conscious indoor applications.
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Opt for Coroplast when you need a durable, cost-effective solution for outdoor messaging.
If you're not sure which substrate is the right fit, our team is here to help you select the best option based on your goals and budget.
