Coroplast vs PVC vs Aluminum Signs: Which Rigid Sign Should You Choose?
Short answer: coroplast is the light, low-cost choice for a single event — directional signs, aisle markers, an H-stake in the ground. PVC board is the step up for a sign that gets reused between shows: rigid enough to hang flat without a frame, light enough to pack in a case. Aluminum composite (ACP) is the one that stays mounted outdoors year round.
All three are UV printed direct to the sheet, single or double sided, and cut to any size from 6" × 6" up to 48" × 96". Here is what actually separates them.
Coroplast — 4mm corrugated plastic
Coroplast is fluted plastic sheet — the same structure as a corrugated cardboard box, made of polypropylene instead of paper. It is the lightest and least expensive of the three, which is exactly why it suits signage that only has to survive one event: a directional sign pointing at a demo station, an aisle marker, a sponsor board, parking and check-in signage outside the venue.
The flutes run vertically as standard, which is the direction that lets a sign sit on an H-stake. A sign wider than 48" runs horizontal flutes instead. There is no laminated surface layer to lift at the edges, and two optional finishes are available: No. 2 brass grommets for hanging or tying to a frame, or a 10" × 30" steel H-stake that pushes into the ground.
Coroplast is also the fastest of the three. Artwork approved before 6am PST ships the same business day.
PVC board — 1/8" expanded PVC
PVC board is a solid 1/8" expanded PVC sheet. No flutes, no visible ribbing — just a flat, rigid face with a smooth matte surface. That is what lets it hang on a wall or sit on a booth frame without looking temporary, while staying light enough to pack flat into a case and reship to the next show.
It sits squarely between the other two: more permanent-looking and stiffer than corrugated plastic, but far lighter to handle and ship than a metal panel of the same size. Grommets are the one optional finishing on this material. It is the indoor workhorse — booth panels, retail and counter displays, reusable directional and menu boards, sponsor and pricing boards.
ACP — 3mm aluminum composite
ACP sandwiches two 0.15mm aluminum skins around a polyethylene core, finished with a gloss UV coating over the print for scratch resistance in handling and transport. Those metal skins are what keep a full-size panel rigid and weather resistant at 4 × 8 feet.
It is the material to specify when a sign stays up: a branded fascia panel above a booth or storefront, permanent exterior signage, outdoor directional and parking signage. Order it with 0.25" punched mounting holes and it arrives ready to bolt up with nothing to drill on site; several corner radius options stop a large panel presenting a sharp square corner at head height.
It is also the heaviest and priciest of the three, so it is overkill for a sign coming down after one weekend.
At a glance
| Coroplast | PVC Board | ACP Aluminum | |
|---|---|---|---|
| Material | 4mm corrugated plastic | 1/8" expanded PVC | 3mm aluminum composite |
| Weight | Lightest | Light | Heaviest |
| Best for | One event, short run | Reused indoor panels | Permanent, outdoor-mounted |
| Typical mount | Grommets or H-stake | Grommets | Punched holes, corner radius |
| Finish | Matte UV print | Matte UV print | Gloss UV coating |
| Max size | 48" × 96" | 48" × 96" | 48" × 96" |
The artwork specs are not the same
This is the detail that catches people out: the three materials do not share one artwork spec.
Coroplast and ACP take a single-page JPEG or PDF per face, in CMYK, at 150dpi or higher, built to the ordered size with no crop marks and no bleed. ACP adds one rule — no Pantone or spot colours, so convert them to CMYK before you export.
PVC board is the exception. It needs a print-ready PDF at 300dpi with a 1/16" bleed on all four sides, because the panel is trimmed after printing and a file with no bleed can leave a visible white edge at the cut.
On any of the three, keep text and logos clear of the trim line, and send one file per face — a double sided sign needs two separate files. Maximum upload is 300MB.
Which should you choose?
- A directional sign, aisle marker or anything that comes down after one event → coroplast
- An indoor panel you will pack up and reuse at the next show → PVC board
- A fascia panel or anything staying mounted outdoors → aluminum composite
All three are quoted per order based on size and finishing. See the full range on the rigid signs page, or read the print coverage guide for more on preparing artwork.
Frequently asked questions
What is the difference between coroplast, PVC and ACP signs?
Coroplast is 4mm corrugated plastic — fluted and light, for short-run signage that only has to last one event. PVC board is a 1/8" expanded PVC sheet, rigid with a smooth face, for indoor panels that get reused between shows. ACP is aluminum skins over a plastic core, the heaviest of the three, for signage that stays mounted outdoors.
Which rigid sign material lasts longest outdoors?
Aluminum composite. Its metal skins keep a full-size panel rigid and weather resistant, and the print carries a gloss UV coating for scratch resistance. We do not publish a rated lifespan, because it depends on exposure, mounting and climate rather than on the panel alone.
Can a rigid sign ship the same day?
Coroplast can — approved before 6am PST, it ships the same business day, and 6:01am to 11:59pm PST ships the next business day. PVC board and ACP ship the same business day when ordered before 12pm PST, or the next business day before 4pm PST. Shipping time is separate and depends on the delivery address.
Do the three materials need different artwork files?
Yes. Coroplast and ACP take a JPEG or PDF at 150dpi with no bleed. PVC board needs a 300dpi PDF with a 1/16" bleed on all sides, since the panel is trimmed after printing.
Can I print both sides?
Yes, on all three. A 4/0 print covers one face and leaves the back white; 4/4 prints both faces. Double sided artwork has to be supplied as two separate files, one per face.
What sizes are available?
All three cut to any size from 6" × 6" up to 48" × 96", made to the dimensions you order rather than a fixed format.