How to Make Foam Board Party Cutouts (Easy DIY Tutorial)

Learn how to make DIY foam board party cutouts using Canva, poster prints, and foam board for birthdays, showers and events.

If you’ve ever looked at a professional balloon installation or party backdrop and wondered how they got those oversized character pieces, aka foam board party cutouts, mixed into the balloons, this is exactly how I make mine.

For this ocean-themed setup, I created my own foam board party cutouts using printed posters, foam boards, spray adhesive, and a little patience. The final result looked custom and high-end without paying for professionally made pieces. If you’re building a full party setup, I also used these cutouts with my balloon styling method. You can read my full balloon garland tutorial here.

These DIY custom foam cutouts ended up being one of my favorite details from the entire party.

The best part is that once you learn the process, you can reuse it for almost anything including birthday parties, baby showers, welcome signs, and any other event signage you can think of. 

This tutorial walks through the exact process I use to create custom foam board cut-outs that look polished and professional.

If you’re planning an entire event and not just the backdrop, I also rounded up some of my favorite party planning shortcuts and ideas here.

This post is all about Foam Board Party Cutouts!

Why Make Your Own Foam Board Party Cutouts?

There are definitely companies that sell custom cutouts, but making your own opens up so many possibilities.

You get:

• Complete control over your custom design
• More affordable pricing for larger sizes
• Faster turnaround
• The ability to coordinate with invitations and décor
• Flexible customizable designs

For this project, I used coordinating artwork from the invitation designer so all of the colors and details matched the rest of the setup.

If you’re creating a special occasion backdrop and want everything to feel cohesive, this method works really well.

Supplies Needed for DIY Custom Foam Cutouts

Here is everything I used:

• Canva
• Digital artwork or a character image
• Poster print (I used Walgreens)
• Foam poster board
• Spray adhesive
• X-Acto knife
• Ruler or straight edge
• Tape
• Two 260 balloons for attaching

Optional:

• Cutting mat
• Extra foam board for larger sizes
• Gloves when using adhesive

My Printing Setup

My preferred setup is:

Poster size: 20×30
Foam board: standard foam poster board
Pickup: same-day local pickup whenever available

One reason I like poster printing instead of fully manufactured custom foam board cut-outs is that I can control sizing and make changes quickly.

Step 1: Create Your Design in Canva

I always start by creating my layout in Canva.

One tip that makes a huge difference: create your Canva file at the same dimensions you plan to print.

Starting at the correct dimensions helps maintain image quality and gives a cleaner final result.

For my setup, I designed each piece individually and arranged them for printing.

If you’re using purchased artwork:

• Make sure your license allows personal use
• Avoid sharing original art files
• Respect the original artist’s terms

You can upload graphics, build your own custom design, or combine multiple elements.

Canva also makes it easy to export files in different formats.

I typically download high-quality files before uploading for printing.

If you’re working with text-heavy welcome signs or event signage, exporting as PDF files can help preserve sharp details.

Step 2: Print Your Poster

Once the design is complete, upload it to your preferred printing service.

I personally use Walgreens because:

• Pickup is usually quick
• Online coupons are common
• Poster quality has worked well for me

I printed everything as 20×30 posters.

That size worked perfectly with standard foam boards and gave enough scale to create impactful foam board displays.

Step 3: Cut Before Gluing

Before attaching anything, cut around the printed image first.

Do not glue immediately.

Lay the pieces onto your foam board and decide placement.

I also recommend leaving a small white border around your image.

This gives a cleaner edge and helps hide small imperfections during cutting.

Trust me on this one.

That tiny buffer makes a big difference in the final professional finish.

Step 4: Attach the Poster to Foam Board

Once placement looks good:

Spray adhesive onto:

1. The back of the poster
2. The foam board surface

Place carefully.

Use a ruler or straight edge to smooth bubbles and wrinkles.

Work slowly and apply with great care because repositioning can wrinkle the paper.

Allow everything to dry completely.

If possible, let it sit overnight before cutting.

This step helps prevent lifting later.

Step 5: Cut Out the Shapes

After the adhesive fully dries, begin trimming.

I used an X-Acto knife.

Take your time.

Slow, controlled cuts will always look better than trying to rush.

This is the stage where your project really starts looking like professionally made custom cutouts.

For detailed areas:

• Rotate the board instead of your hand
• Replace dull blades
• Cut in multiple passes

If making larger sizes, work in sections.

Step 6: Attach to Balloon Garlands or Backdrops

Once the cutouts are finished, it’s time to install.

For my ocean setup, I taped two 260 balloons onto the back in a hashtag pattern.

That gave enough flexibility to weave the pieces into my balloon garland.

You could also attach these to:

• Backdrop stands
• Walls
• Easels
• Foam board displays
• Photo booth setups

This method held surprisingly well and allowed me to move pieces around while decorating.

Ways to Use Foam Board Cutouts

Now that you know how to make them, here are ideas beyond this project:

Birthday Party Decorations

Characters, names, age signs, and oversized décor.

Bridal and Baby Showers

Baby animals, bows, florals, themed backdrops. Check out one of my favorite bridal showers I ever hosted here.

Welcome Signs

Coordinate colors with invitations.

Event Signage

Menus, directional signs, seating displays.

Photo Booths

Create oversized props and backgrounds.

Themed Parties

Sports, construction, under the sea, princess, holiday themes.

Once you start making custom foam cutouts, you’ll probably find yourself planning excuses to use them.

Frequently Asked Questions

What kind of foam board should I use?

I usually use standard foam poster board from Dollar Tree, Walmart, or a craft store.

For larger sizes or pieces that need extra support, upgrade to thicker foam board.

What size poster should I print?

My favorite size is 20×30 because it works well with standard foam boards and creates a big visual impact.

You can absolutely go smaller or larger depending on your project.

Can I make these without a Cricut?

Yes.

I didn’t use a Cricut at all for this project.

I simply printed the poster, attached it to foam board, and cut it by hand using an X-Acto knife.

Can I create my own artwork?

Absolutely.

You can create your own custom design in Canva or purchase artwork from a designer.

If you’re using purchased artwork, make sure you follow licensing terms and avoid redistributing original files.

What’s the best file type to upload for printing?

I usually upload high-resolution image files.

For designs with a lot of text, welcome signs, or event signage, PDF files can sometimes keep edges looking sharper.

How do you attach foam cutouts to balloon garlands?

I taped two 260 balloons to the back in a hashtag pattern and tucked them into the balloon structure.

You could also use fishing line, zip ties, easels, hooks, or backdrop stands.

Can these be reused?

Sometimes.

If removed carefully and stored flat, many of mine have held up for future parties or photos.

What events work well for foam board cutouts?

These work for almost anything:

• Birthday party setups
• Baby showers
• Welcome signs
• Photo booths
• Event signage
• Graduation parties
• Holiday displays
• Themed parties
• Business events

How do I make them look more professional?

Three things made the biggest difference for me:

1. Start with high-resolution artwork
2. Leave a tiny white border while cutting
3. Smooth the poster thoroughly before drying

Those small details help create a more professional finish.

Save This DIY for Later

If you’re planning a party and want custom cutouts without custom pricing, save this tutorial for later and tag me if you make them. I would love to see your version.

Final Thoughts

This project took more time than money and ended up becoming one of my favorite party DIYs.

The finished setup looked custom, elevated, and honestly way more expensive than it was.

If you’re planning a special occasion and want that big visual impact without ordering pre-made pieces, I highly recommend trying this method.

A little foam board, a printer, and some patience can go a long way.

As always, thank you for following along with me in my creative journey. Be sure to tag me and use #meagannicholedotcom when sharing your DIY! Thanks for stopping by MeaganNichole.com

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