6-Foot Foam Freestanding Greek Letters

Custom 6-Foot Freestanding Greek Letters – EPS Foam / Outdoor & Indoor Event Display

I am seeking an experienced foam fabricator/prop designer to design and fabricate two oversized, freestanding Greek letters: Beta (Β) and Gamma (Γ) for use by an Alpha Phi Alpha Fraternity, Beta Gamma chapter.

The finished pieces will be used as a high-impact photo/display installation at outdoor Homecoming/tailgate events as well as indoor fraternity events. I want the design to be simple, bold, upscale, and professional.

Project specifications:
Letters: Greek Beta (Β) and Gamma (Γ)
Height: Approximately 6 feet tall each
Material: High-density EPS (expanded polystyrene) foam
Depth/thickness: Approximately 8–12 inches, or fabricator's recommendation for appearance, durability, stability, and transportability
Color: Alpha Phi Alpha colors — black with metallic/gold detailing or trim
Finish: Smooth, professional finish suitable for photography
Outdoor use: Must have an appropriate protective/hard coating and paint system for temporary outdoor event use, including normal sun and humidity
Indoor use: Finish should be clean and refined enough for indoor receptions, photographs, and formal chapter events
Weight: Pieces should remain lightweight and reasonably easy for one or two adults to transport
Stability: Each letter should have a stable, preferably removable base/stand or discreet anchoring system appropriate for temporary outdoor use. Or a recommendation for stablization. Please recommend the safest solution. The letters should not easily tip or blow over under normal event conditions.
Fabrication: I anticipate the letters being digitally designed and CNC/hot-wire cut from EPS foam, then hand-finished, coated, and painted. However, I am open to the fabricator's recommended process if it produces a superior finished product.
Design files: Please include the final CAD/vector/CNC-ready design files as part of the project deliverables.
Optional Add-On
Please provide a separate price for a smaller, removable ΑΦΑ (Alpha Phi Alpha) piece designed to coordinate with the ΒΓ letters.
The ΑΦΑ piece could potentially sit above the ΒΓ letters as a removable topper or be used independently at other events. It should have the same black-and-gold finish.

This is an optional component, so please quote:
Option A: ΒΓ only
Option B: ΒΓ + removable ΑΦΑ topper/display

When Submitting Your Bid
Please provide examples/photos of previous large EPS foam letters, dimensional signage, event props, scenic fabrication, or similar CNC/hot-wire foam work.
Please also include your recommendation regarding:
Best foam density/type
Recommended letter depth
Protective coating for repeated indoor/outdoor use
Base/anchoring design
Approximate finished weight of each letter
Production timeline
Shipping/freight costs to Hampton, Virginia 23666
Total fabrication cost
The goal is to create something that looks custom and substantial while remaining lightweight, portable, and reusable for many years.
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