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Royal Foam engineers and fabricates stunningly realistic oversized product replicas that command attention at trade shows, product launches, and in retail.
GET MY FREE REPLICA QUOTENothing announces your brand louder than an oversized product replica. Picture a flawless, jumbo 3-D twin of your item—built to dazzle the eye, shrug off wear, and stay light on the scales. Its job is clear: render your product unmissable.
Set as the physical focal point, it draws press, influencers, and shoppers, sparking share-worthy moments that forge unforgettable brands and keep them talking for weeks.
Total Control. American-Made Quality
Every build phase—from 3D model design to final flawless paint—happens entirely in our 45,000 sq. ft. US facility. Why? It lets us control quality, timelines, and every critical detail. Our promise: No surprises, no delays—just a perfect, large-scale replica delivered on time for your big launch.
An Obsession with Realism
We’re not just a vendor—we’re your off-site team. From the first 3D scan to the final shipment, we run the entire project. Pass us the specs, deadlines, and surprises; we’ll handle them all. You stay focused on one thing: a knockout market debut. Pure impact.
Monumental Scale, Minimal Headaches
Our large-scale foam props have the presence of a stone statue without the logistical nightmare. This means they’re easier and cheaper to ship, faster to set up and perfect for any venue—from a packed trade show floor to a high-street retail pop-up.
Designed to Be Shared
We don’t just build props; we build photo-op machines. Our 3D models are designed from the ground up to be interactive centerpieces that people feel compelled to photograph and share online. The result? Massive organic reach, powered by your own audience.
Your Project Partner, From Start to Finish
From the first pin-point 3D scan of your product to the final freight run before launch, we’re right beside you the whole way. We sweat every detail—routes, specs, deadlines—so you can pour your energy into the impact that truly counts.
Quotes in Hours, Not Days
We know your timelines are tight. That’s why you’ll get a comprehensive, solid quote from us within hours. No waiting, no guessing. Just the numbers you need to plan your next move with confidence and speed.
We’re ready to review your specs. To ensure we start with maximum precision, email your essential project files—your CAD drawings, 3D models (if possible, please use .obj or .stl formats), or any supporting technical documentation—directly to our dedicated Project Intake address below.
Our engineers will review your model for large-scale production, then send back a detailed quote covering the timeline and finishing options. Once you approve, we get to work.
When your giant replica is complete, we’ll notify you. Finally, we secure your finished replica inside a purpose-built transport crate and manage the delivery logistics straight to your door—be it the event floor, the warehouse bay, or the retail storefront.
Fill out our form or call us at (904) 345-5400. Tell us about your product and your goals for the replica. We can often provide an estimated cost and timeline on the first call.
Send us your product—we’ll treat it like gold. Our team will scan your product with advanced technology to create a perfect, high-resolution 3D model. We’ll then send the digital proof to you for approval.
We don’t just package your project; we custom-engineer a robust, secure shipping crate designed precisely around your unique dimensions. Consider this your final guarantee: your spectacular, high-impact piece will arrive at the event site, the distribution warehouse, or that flagship retail location in absolutely pristine, launch-ready condition. It’s about eliminating uncertainty, ensuring your replica is protected and delivered exactly when you need it.
Building a flawless, large-scale replica of a highly detailed product is never a simple task; it’s a genuine feat where engineering meets artistry. At Royal Foam, we haven’t just learned the ropes—we’ve rigorously perfected a process specifically designed to guarantee absolute, uncompromising fidelity to your original product.
This ensures your brand is always represented on a grand scale with the impeccable quality and precision it truly demands.
As the leading US fabricator of foam oversized product replicas, we follow a meticulous, quality-obsessed process.
Stop attendees in their tracks and pull them to your booth. A giant replica of your product is the ultimate conversation starter and the most memorable feature on a crowded show floor.
Launch a new product or highlight a bestseller with an unmissable in-store display. A large-scale replica creates a premium feel and drives sales directly at the point of purchase.
Create the ultimate “Instagrammable moment.” Our 3D product models are designed to be the centerpiece of any pop-up or brand activation, generating massive amounts of user-generated content.
Make your new product a legend from day one. Unveiling a giant version of your product creates a dramatic, press-worthy moment.
Turn your flagship product into a permanent work of art. A custom foam sculpture in your lobby is a powerful statement of brand pride and innovation.
Focus on the Impact. We’ll Perfect the Process
Stop Compromising. Start Building!
Let’s turn your boldest idea into a physical landmark!
Standard production time is 4-8 weeks from design approval to completion. Rush projects are sometimes completed in 2-3 weeks, depending on complexity and current production schedules.
There are virtually no size limitations with custom foam fabrication. Individual foam blocks can be seamlessly joined to create installations 20, 30, or even 40+ feet tall.
Absolutely. Thanks to a special urethane coating, our EPS foam is highly weather-resistant and unaffected by rain, humidity, temperature changes, or UV exposure. The material won’t deform, rot, or decay like wood, and it won’t rust like metal structures.
Yes. Custom 3D models (e.g., for electronics exhibitions) often incorporate LED lighting, projection surfaces, audio components, or interactive displays. The material is easily modified to accommodate wiring, mounting points, and electronic components while maintaining structural integrity. You can discuss options for such models with our manager individually.
They are built to last. We use a strong, protective hard coat that resists dings, scratches and scrapes, making them more than tough enough for busy trade show floors and even multi-city marketing tours.
We can go as big as you dream—practically no limits. Our huge 45,000 sq. ft. shop and top-tier fabrication tricks let us build replicas at whatever scale you need, from 6 feet all the way up to 60 feet tall.
Each replica travels in a tailor-made crate, reinforced with wood and steel and engineered just for that piece. This keeps it fully protected in transit and guarantees it shows up in flawless shape, every time.
Absolutely. Our team includes finishing artists who are masters of faux finishing techniques. We can convincingly replicate the exact look, texture, and patina of nearly any premium material you specify.
Yes, both are great options. Contact us to discuss your project and we’ll help you decide which is best for you, whether it’s one of our custom inflatable product replicas for a mobile tour or a solid foam piece for a permanent display.
Absolutely. Every inflatable replica needs a steady blower to hold its form. Be sure you have consistent power—whether that’s a regular wall outlet or a portable generator—to keep it inflated inside or outside, anywhere.
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