Exoboard: Shape the extraordinary

Cut to any shape you can imagine with Exoboard. Our rigid display board is precision-cut to your exact specifications, printed in high definition and made from over 50% recycled PVC. Here's everything you need to know and what you can make with it – from personalised football cards and themed photo booth props to promotional display boards.

What is Exoboard?

Exoboard is a rigid-but-lightweight display board – a multi-layer PVC foam sheet containing over 50% recycled PVC, printed in high resolution using advanced flatbed technology, then contour cut to any shape specified in your artwork file.

The name is inspired by exoskeletons: rigid on the outside, with a lightweight foam core that makes it easy to handle without sacrificing structural stability. The foam layer exists to keep the board light and to make contour cutting cleaner and more precise, giving you smooth, accurate edges wherever the cutter follows your vector path.

The result is a board that feels substantial in the hand, lies flat and stable for display, and holds flatbed-printed colour with the same sharpness you'd expect from a photographic print. It's fully waterproof, suitable for both indoor and outdoor use, and fully recyclable.

What can you make with Exoboard?

Exoboard suits any product that needs a rigid display format cut to a shape other than a standard rectangle. The flatbed cutter follows a vector path embedded in your PDF, so the finished board matches your artwork exactly – no trimming or hand-finishing required.

Sports cards & collector formats

Personalised football cards, trading cards and collector-format products. Standard card dimensions or fully custom sizes – both work cleanly, especially with rounded corners at 3mm or above.

Retail signage & point-of-sale displays

Custom-shaped shelf talkers, branded standees and point-of-sale display boards for retail environments, pop-up events and exhibitions.

Event props & photo booth accessories

Letter boards, number shapes and themed photo booth props. Exoboard's rigidity means props hold their shape without warping, even in busy event environments.

Name plaques & branded panels

Custom-shaped office signage, door signs, reception panels and branded wall displays. The smooth surface wipes clean and holds colour well under indoor lighting.

Shaped art prints & display pieces

For artists and photographers looking to offer something beyond a standard rectangle – silhouette cuts, custom shapes and prints as premium product options.

Sustainable branded merchandise

Branded display items and custom merchandise where sustainability matters – Exoboard's recycled PVC content and recyclability make it a credible lower-impact choice.

How it's made

Every Exoboard starts with your artwork file. We print directly onto the board surface using our flatbed printers, which apply colour across the entire surface – edge to edge, corner to corner – at high resolution. The flatbed process is what gives Exoboard its sharp detail and consistent coverage: there's no colour fade, banding or uneven coverage, even on large formats.

Once the board is printed, the cutter reads the CutContour vector path embedded in your PDF and follows it precisely, cutting the board to your exact shape. The cut edge is clean and smooth, with no rough finishing or hand-trimming needed.

Bleed – the 1.5mm extension of your artwork beyond the cut line – prevents any white edge from appearing where print and cut tolerances interact. Your finished board looks exactly as it does in your design file.

Exoboard at a glance

Rigid PVC with a foam core made from recycled materials, cut to any size or shape.

• Multi-layer PVC foam sheet
• Custom cut to any size or shape
• Rigid, lightweight and durable
• Fully waterproof and recyclable
• Contains over 50% recycled PVC
• Smooth, printable surface
• Vibrant, high-resolution print
• Suitable for indoor and outdoor use

Read more

File requirements: what you need to supply

File format

Single-page PDF/X-4 at 1:1 finished size

Colour mode

RGB, 300 DPI minimum

Bleed

≥ 1.5mm beyond the cut path on all sides

Cut path

Vector path, spot colour named exactly CutContour

Cut path stroke

1pt, no fill, overprint ON, topmost layer

Minimum outer size

15mm in any direction

Minimum inner radius

3mm for Exoboard

Minimum peninsula width

3mm

PDF export

Vectors preserved, spot colours included, transparency not flattened

The most common file mistakes are using standard RGB magenta for the cut path instead of a true spot colour, and omitting bleed.

How to start selling Exoboard

Exoboard is available through the Prodigi dashboard, print API and all ecommerce integrations. There are no minimum order quantities – you can order a single board to test your file, then scale up as demand grows.

Prodigi Pro users get 15% off pricing, including for Exoboard, along with branded packaging inserts and advanced features for scaling businesses.

Want to test the quality first? Order a custom sample and claim 50% back on the order total – it's the fastest way to see and feel the product before committing to a product line.

Frequently asked questions

What is Exoboard?

Exoboard is a rigid display board made from a multi-layer PVC foam sheet containing over 50% recycled PVC. It's printed in high resolution using flatbed technology and contour cut to any custom shape. The name references 'exoskeleton' due to its rigid outer shell structure and lightweight foam core. Exoboard is fully waterproof and suitable for indoor and outdoor use.

What can Exoboard be used for?

Personalised football cards, promotional display boards, themed photo booth props – if you can design it, we can cut it. Any application that requires a rigid, lightweight display board cut to a non-rectangular shape is a good candidate for Exoboard.

Is Exoboard sustainable?

Yes. Exoboard contains over 50% recycled PVC and is fully recyclable at end of life. Prodigi prints using water-based, eco-friendly inks and ships in Ecocaps – 100% recycled packaging. It's a lower-impact alternative to standard PVC display boards without compromising on performance.

What type of file do I need to supply?

A single-page PDF/X-4 at 1:1 finished size, RGB colour mode, 300 DPI minimum, with at least 1.5mm bleed beyond the cut line and a vector CutContour spot colour path on the topmost layer.

Is there a minimum order quantity?

No. Like all Prodigi products, Exoboard has no minimum order quantity at any account tier. Order a single board to test and check print quality, or place any volume as needed. Prodigi Pro users receive 15% off product pricing.

Ready to shape something extraordinary? Free to sign up. No minimum orders. Only pay when you make a sale. Get started or order a sample