The artwork is final. The export is sitting on your desktop, and the only decision left before checkout is a dropdown of six foam board sizes, none of which you have ever held. The file is the same no matter which one you choose, yet the board has to survive a countertop, an entrance, a standee or a full photo wall.
Size is the easy half of that decision. The harder half is the board depth, and it is the half that decides whether the panel is still flat at the end of the day. This guide walks the six standard dimensions in real millimetres, then works through thickness, strut backing, indoor limits and custom quotes so you order once.
The short version
- Six board sizes run from A4 at 210 x 297mm through A3 297 x 420mm, A2 420 x 594mm, A1 594 x 841mm and 600 x 900mm to A0 at 841 x 1189mm.
- 5mm is the standard thickness for everyday indoor signage; 10mm is the large format choice.
- Both thicknesses are available at every size in the range.
- Strut Backing is only available on one sided boards.
- Foam board is for indoor use only.
- No minimum order applies, so you can order one board.
| Size | Dimensions (W x H) | What it suits | Thickness to pick |
|---|---|---|---|
| A4 | 210 x 297mm | Desk cards, table talkers and small signs read up close | 5mm |
| A3 | 297 x 420mm | Reception signs and small rigid posters with more presence | 5mm |
| A2 | 420 x 594mm | Easel signs, point of sale and window displays | 5mm, or 10mm if it will stand unsupported |
| A1 | 594 x 841mm | Entrance signage, trade show panels and large seating charts | 10mm |
| 600 x 900mm | 600 x 900mm | Property boards and wider floor standing displays | 10mm |
| A0 | 841 x 1189mm | Life size cutouts, standees and large photo walls | 10mm |
Foam board sizes from A4 to A0, measured in real millimetres
Six fixed sizes cover the range, and none of them are approximate. Each step changes what the board can do in a room, not just how large it prints.
- A4, 210 x 297mm: the smallest panel, made for table talkers, menu boards and counter cards where the viewer is standing close enough to read small type.
- A3, 297 x 420mm: a step up in presence for reception signs, table numbers and small posters mounted rigid rather than framed behind glass.
- A2, 420 x 594mm: the practical retail format for easel signage, point of sale, welcome signs and window cards that need to hold a room corner.
- A1, 594 x 841mm: the first true entrance format, built for event signage, trade show panels and large seating charts that have to guide a crowd.
- 600 x 900mm: a wider alternative to A1, made for property boards, event and venue signage and floor standing displays that need a broader face.
- A0, 841 x 1189mm: the largest board, intended for full life size cutouts, standees, large format entrance signage and photo walls where one panel carries the room.
The 600 x 900mm board is the one size that catches people out. It is not part of the A series. It exists because it matches the common corflute signage format, which is why it keeps appearing on property boards and venue signs rather than in the A4 to A0 paper logic.
Foam board thickness: when 5mm is enough and when 10mm is worth it
Every size in the range for foam board printing in Australia is built on the same choice of core depth: 5mm or 10mm. Both thicknesses are available at every size, which means the decision is never locked by your selection of A4, A1 or A0.
5mm uses the standard core depth. It keeps the panel light enough to carry under one arm while both paper faces take the same full colour print. Most indoor signage can stop here. 10mm doubles the core depth, and that extra material does three practical things: it helps larger formats resist bowing, it gives a deeper visible white edge, and it makes the board more tolerant of repeated handling.
The rule is simple. The step up starts to earn its money at A1 and above. A 10mm board is the choice for A1, 600 x 900mm and A0 panels, for pieces that get moved around often, and for displays that stand on their own. A4 and A3 desk signs rarely need it unless they will lean against an uneven surface all day.
Indoor use only: the material reason behind the rigid surface
A foam core board is a polystyrene foam core with a smooth paper liner on both faces. The paper faces are the reason the board prints the way it does. Full colour direct UV printing is applied straight onto the board, which bonds the ink to the surface rather than sitting on a vinyl film. That is also the limit of the material.
Foam board is for indoor use only. The foam core is not weatherproof and is sensitive to heat and moisture, which can cause warping and surface damage. The core is heat affected at 85 degrees Celsius and above. A board left in a car boot during an Australian summer is a board at risk. Rain between the car park and the venue is the failure everyone discovers once, usually while the board is still under one arm.
Outdoor work is better served by foamed PVC signage boards, which are rigid and weatherproof in ways this board is not. If the job has to live outside, choose the outdoor board from the start rather than hoping the weather holds.
Single sided, double sided and the strut backing rule that surprises people
One sided printing leaves the reverse face plain white while the front carries full colour artwork. The board is paper faced on both sides, so the unprinted side still looks clean when it is mounted against a wall. Double sided printing puts artwork on both faces, which suits free standing and hanging displays and signage seen from both directions. It also lets a second message or a second language sit on the back.
Strut Backing adds a fold out cardboard support fixed to the reverse face, turning the board into a free standing display with no easel required. It is available on every size, including A0, and is priced per board. Because the strut is fitted to the reverse, it is only available on one sided boards. The default is No Strut, and that is the right choice when the panel will be mounted, hung, leaned or displayed on an existing stand. A board without a strut needs an easel, a stand or wall mounting.
The planning consequence is direct. If the sign has to be readable from both directions it needs a stand, and if it has to stand on its own it can only speak in one direction. When the shape itself becomes the display, the flat panel becomes the wrong tool; that is where point of sale standees take over.
Custom sizes, router cut shapes and the ceiling at 1200 x 2400mm
The product page sells six standard sizes and no others. Rectangle trims the board square to the selected size with straight edges. For shaped work, custom shape foam board cutting is a router cut that follows any outline. You supply artwork only and the Paperlust team builds the cutting line, so no vector cut file is needed.
Common shapes are arched tops, logo shapes and life size figure cutouts. Custom Shapes is charged per order, not per board, which means the cost is not multiplied across a batch the way price-per-print would be. Intricate or three dimensional shapes go through custom quoting rather than the page price.
A size outside the six listed is also a custom quote, not an option you can select and price online. The flatbed press has a maximum sheet of 1200 x 2400mm, which is the physical ceiling on any custom size conversation. It is not a limitation of goodwill. It is the size of the machine, and it sets the upper boundary before another process takes over.
Ordering one board, ordering fifty, and what it costs to start
There is no minimum order. Quantity breaks run through 1, 2, 3, 5, 10, 20, 50 and 100 with a published price at every break. A single board is a normal order, not a sample exception.
The entry price is $68.95 including GST for one A4 board at 5mm, printed one side, rectangle cut and no strut. The per board price falls substantially as the quantity climbs, which is the reason to order the spares in the same run rather than reprinting one board later. Boards are printed in Australia, made to order, and delivered Australia wide.
If the job starts as a poster and becomes a board, our guide to A1 poster size in Australia is useful for checking the original print dimensions, and the separate guide to mounting a poster on a rigid board walks through display options when the panel is not standing alone.
Frequently asked questions
What foam board sizes are available?
Six foam board sizes are available, all measured width by height. They are A4 210 x 297mm, A3 297 x 420mm, A2 420 x 594mm, A1 594 x 841mm, a 600 x 900mm board, and A0 841 x 1189mm. The 600 x 900mm sheet is not part of the A series. It matches the common corflute signage format, which is why it works for property boards and wider venue signage. Foam board is sometimes called foamcore, but the product is the same rigid paper faced panel.
What is the difference between 5mm and 10mm foam board?
Both thicknesses are available in every size. 5mm uses the standard core depth and keeps the panel light; it suits most indoor signage because both paper faces still take full colour print. 10mm doubles the core depth, which helps larger formats resist bowing and produces a deeper visible white edge. 10mm is the choice for A1, 600 x 900mm and A0 boards, when repeated handling is likely, and when the board will stand unsupported without a backing frame.
Can foam board be used outdoors?
No. Foam board is for indoor use only. The foam core is not weatherproof and is sensitive to heat and moisture, which can cause warping and surface damage. The core is heat affected at 85 degrees Celsius and above, so a panel left in a hot car or near direct sun can begin to fail even before rain reaches it. For any outdoor sign, corflute is the rigid weatherproof recommendation.
Can a strut be added to a double sided board?
No. Strut Backing is fixed to the reverse face, so it is only available on one sided boards. Double sided printing puts artwork on both faces, which suits displays seen from both directions or a second language on the back, but it leaves no clean face for the fold out support. If a board needs to stand on its own, it can only be printed on one side. If it needs to speak in both directions, it needs an easel, a stand or wall mounting.
Can I order a custom size that is not listed?
Yes, through a quote rather than the online selector. The page sells the six standard sizes and no others, so a size outside that list is a custom quote rather than something you can price yourself. The flatbed press that prints the boards has a maximum sheet of 1200 x 2400mm, which sets the physical ceiling. Custom Shapes is a separate router cut option for outlines such as arched tops, logo shapes and life size cutouts, and intricate or three dimensional shapes are quoted separately.
Can I order just one board?
Yes. There is no minimum order, and quantity breaks run through 1, 2, 3, 5, 10, 20, 50 and 100 with a published price at every break. A single board is a normal order, not a sample exception. The entry price is $68.95 including GST for one A4 board at 5mm, printed one side, rectangle cut and no strut. Ordering one board is sensible for a proof or a replacement, but the per board price falls substantially as the quantity climbs.
