Giant Tennis Ball Mockup in EPS Foam and Resin

This project combines technological precision with hand finishing, showing how EPS foam can be transformed into a solid design object with real visual impact.

Making the mockup started with accurate digital design, essential for handling such large dimensions:

1. Technological Cutting: We used CNC hot-wire technology to cut the precise sections of the sphere.

2. Hand Modelling: Once the foam sections were assembled, our craftsmen shaped the piece by hand, refining the silhouette to ensure perfect sphericity.

In line with the client’s requirements — which called for excellent value for money and fast delivery — we opted for a coating of cementitious resin..

This technical choice achieved two key results:

• Structural strength: The resin protects the foam core, making the mockup suitable for display during the event.

• Embossed Effect: The nature of cementitious resin made it possible to quickly replicate the typical “rough”, porous texture of real tennis balls, avoiding lengthy surface finishing processes.

The final stage involved colour customisation. We used professional enamels , closely following the palettes specified by the client, ensuring bright colours and a visual identity consistent with the sporting event’s brand.