Substrate thickness drives rigidity, weight, and how the piece mounts or stands. Too thin and it flexes or tears; too thick and it may not fit the frame or may cost more than needed.
Rigidity and handling
Thin foam board or vinyl bends easily and can crack when handled or mounted. Thicker substrate stays flat and survives install and transport. For large pieces, thickness is critical.
Mounting and hardware
Standoffs, frames, and mounts are sized for certain thicknesses. Ordering a thickness that does not match the hardware causes install issues. Confirm the mount or frame before locking substrate thickness.
Specifying thickness
• State size and whether the piece will be freestanding, framed, or wall-mounted.
• If you have existing hardware, give the required thickness.
• For large format, ask the printer for the minimum thickness they recommend.
Common mistake
Choosing the thinnest (cheapest) option for a large sign. It will flex, wave, or crack. Match thickness to size and use.