Panel Signs & Banners – Large Format Printing – What Works and Why

When it comes to large format printing for outdoor use, not all materials are equal. Some are perfect for temporary signage, others can take a beating from Irish weather for years. I’ve worked with all the common substrates, so here’s a no-nonsense breakdown to help you choose what’s best depending on your needs and budget.

Corriboard – The Basic Budget Option

Corriboard (also known as correx) is a fluted plastic sheet that comes in 4 mm thickness as standard, though versions in 5, 6, or even 7+ mm exist. It’s lightweight and super affordable, which makes it perfect for short-term use like event signage or temporary site boards.

Pros:

• Cheap and cheerful
• Lightweight, easy to install or remove
• Can be zip-tied, screwed, or glued temporarily

Cons:

• Not very durable in strong wind or rain
• Warps easily, especially with UV exposure
• Doesn’t look premium at all

Corriboard can be laminated with matte or gloss film to add a bit more weather resistance and improve longevity, but I still wouldn’t recommend it for anything long-term.

Foamboard – Clean Finish and Great for Custom Shapes

Foamboard, usually in 3–5 mm thickness, is more popular for indoor use, but it can be used outside in dry, calm conditions for very short-term signage. The main advantage is that it cuts easily into custom shapes, making it ideal for one-off displays or quirky design pieces.

Pros:

• Very clean and professional look
• Easy to mount

Cons:

• Doesn’t handle moisture or humidity
• Not suitable for anything permanent outdoors
• Prone to delamination without protection

If you need something eye-catching for a day or two – and the weather’s on your side – foamboard could work. But again, UV and rain will destroy it quickly without proper lamination.

Aluminium Composite Panel – Best Value for Long-Term Use

Also known as Dibond or Skybond panel, this 3 mm aluminium composite board is, hands down, the best value for outdoor durability and appearance. It’s a sandwich of two aluminium skins with a plastic core, making it extremely rigid and weatherproof.

Pros:

• Handles rain, sun, and wind with no problem
• Doesn’t bend or warp
• Professional, clean look
• Lasts for years with minimal maintenance

Cons:

• Heavier than corriboard
• More expensive – but still affordable considering the durability

Any sign I produce on aluminium board for outdoor use gets laminated – either matte or gloss depending on client preference. This adds UV protection and scratch resistance, which is a must if the sign will be near roads or foot traffic.

Outdoor Banners – Versatile, Scalable, and Durable

For fencing, scaffolding, or temporary branding, banners are unbeatable. I produce banners from PVC materials starting at 440 GSM and going up depending on durability requirements. You can choose:

• Standard PVC banners – classic, strong, and effective
• Blockout banners – perfect for double-sided prints or blocking backlight
• Mesh banners – ideal for windy areas like fences or hoardings, as the perforated surface reduces wind resistance

Banners are typically eyeletted every 0.5 m for standard sizes, and every 1 m for larger installations. They can be printed up to 1.6 m wide per panel and joined together with welded seams – so there’s basically no limit to how big you want to go.

How I Print – No Corners Cut

All my prints are produced on an Epson SureColor large-format printer using eco-solvent inks. These are quick-drying, low-odour, and extremely scratch-resistant, even without lamination. That said, I always recommend laminating outdoor prints for the best UV protection and durability.

Even if you don’t go with the top-tier material, the printing process I use ensures high-quality colour, clarity, and resistance to the elements.

Need Advice? Just Ask

Every project is different, and that’s why I don’t believe in one-size-fits-all. If you’re unsure which material suits your use case, whether it’s for a one-day event or a five-year installation – I’m happy to advise. I’ll always suggest what fits both your expectations and your budget.