I am a CNC operator, assembler, and installer for a foam shapes company. We have been making movie props, themed environments, and architectural features for 30 years. AMA
I'm sitting here with an engineer that has been with the company for 20+ years. He should be able to help answer any difficult technical questions that redditors may have. Ask us anything!
Proof: Facebook Page
Update: Thanks for the thoughtful questions and support Reddit. We enjoyed answering you yesterday! We'll be here today to answer any additional questions that you may have.
We have tons of pictures from projects over the years - but we're new to social media, so stay tuned to our Facebook Page to see cool shapes we've made as we upload them.
We also make monument signs (development signs, church signs, office signs) with foam. You can see photos at: http://axisign.com