Giant 3D Letters and Photo Walls from Honeycomb Board for Events
Names, initials and hashtags two metres tall are the most photographed thing at a wedding or launch. Here is how decorators build them from paper honeycomb instead of plywood.
Giant 3D letters and photo walls made from honeycomb board are rigid, free-standing decorations cut from paper honeycomb sheets, finished with paint or laminated print, and light enough for one person to carry into the venue. Decorators use them for wedding initials, company names at product launches, festival hashtags, birthday numbers and branded photo walls. After the event they go into ordinary paper recycling instead of a skip.
This article covers the two ways giant letters are built, how photo walls are assembled and braced, what honeycomb changes against plywood and MDF on cost per event, and where it is the wrong material. It applies to standard kraft honeycomb board of the kind phb manufactures in Balakong, Selangor, Malaysia.
How giant 3D letters are built from honeycomb board
There are two methods. Solid letters are cut straight from thick board, 30–50mm, with a CNC router or a sharp knife and a template; they are quick to make and suit letters up to about waist height. Box letters are built like a hollow shell: a front face and a back cut from thin board, joined by strips of board along the edges, which gives real depth for large letters while keeping them light. With sheets up to 2.4m x 1.2m, a single letter can reach 2.4m tall without a join in the face.
Finishes are paint, vinyl or a printed sheet laminated to the face. Mirror vinyl, glitter paper and fabric wraps are common for weddings; laminated full-colour print suits brand launches. A wider base, a hidden rear foot or a weighted plinth keeps tall letters upright on a smooth ballroom floor.
How a honeycomb photo wall goes up
A photo wall is a row of honeycomb panels with a printed or decorated face, joined edge to edge and held upright by rear braces or slot-in feet. Panels arrive flat, one person can carry each, and a two-person crew can stand a wall of several panels in a short setup window. Because the board stays flat, a laminated print does not ripple under venue lighting, which matters when every guest photographs it.
As an illustrative example, a decorator doing weekend weddings might keep one set of plain honeycomb panels and re-face them with a new print or fabric for each couple, so the structure is reused while the design changes.
What it changes against plywood and MDF
Plywood and MDF letters are heavy, need a workshop to cut and a lorry and two people to move, and are hard to store or dispose of. Honeycomb letters are cut with lighter tools, carried by one person and stored flat or stacked. At the end of an event that does not need the piece again, it goes into paper and cardboard recycling because the board is mono-material kraft paper.
Per sheet, honeycomb costs more than foam board and less than MDF at similar rigidity. Per event, once transport, setup labour, storage and disposal are counted, it is usually the lower-cost rigid option for decorations that stand for a day or a weekend.
Where honeycomb is the wrong choice for letters and photo walls
Standard honeycomb is not waterproof: outdoor garden weddings and open-air festivals need laminated or coated builds and cover from rain, and a letter left overnight on wet grass will soften at the base. Paper is combustible, so keep letters away from candles, pyrotechnics and hot lamps, and follow the venue fire rules; use only low-heat LED lighting with fittings suitable for the purpose. Tall pieces in windy outdoor spaces need weighted bases or ties. For permanent signage that stays up for years, acrylic or metal is the better choice.
Frequently asked questions
What are giant letters for weddings made of?
Common materials are plywood, MDF, foam and paper honeycomb board. Honeycomb letters are rigid, light enough for one person to carry and can be painted, wrapped in fabric or faced with vinyl or print. They are cut solid from thick board or built as hollow box letters, and go into paper recycling when no longer needed.
How tall can a honeycomb board letter be?
Honeycomb sheets come up to 2.4m x 1.2m, so a single letter can be cut up to 2.4m tall without a join in the face. Taller pieces are possible by joining panels. Tall letters need a wider base, a rear foot or a weighted plinth to stand safely, especially on smooth floors or outdoors.
Where can decorators in Malaysia buy honeycomb board for giant letters?
phb manufactures honeycomb board in Balakong, Selangor, and supplies sheets from 10mm to 50mm thick in sizes up to 2.4m x 1.2m to event decorators and prop makers. Ask for a sample kit to test cutting and finishing, or send your letter sizes by WhatsApp on +6016-891 6381 for a quote on the sheets.
Plan your next set of giant letters
Send us the words or initials, the height you want and the finish. We will suggest a thickness and build method and quote the honeycomb sheets for the job.