Imagine It With EPS Foam!

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Steve Morrone

Steve Morrone ©Steve Morrone ~ Photo used with permission

Meet Steve Morrone, an ICA customer originally from Levittown in Bucks County, PA who creates extraordinary environments with EPS foam. Steve now resides in Southern New Jersey, where he founded Imagine Factory, LLC in 1997. He first began sculpting and painting when he was working on the Mummers set designs in 1985 and 1986. After beginning his career with non-profit work, utilizing free foam he would come by, he started looking to expand his reach and follow out this creative endeavor as a career path.

CNC machine is used to cut EPS foam into custom designs

CNC machine ©Steve Morrone ~ Photo used with permission

As his business expanded, Steve noticed the quality of his materials and tools evolve over time as well. He started out using chainsaws to shape his EPS foam into recognizable sculptures. Then he discovered the hot wire tools and now he, along with Nick Corso who heads up their new digital production department, are integrating their new CNC (Computer Numerical Control) machine, or digital shape cutter, to maximize fabrication efficiency.What a long way things have come. While Steve appreciates the latest technology, he still enjoys producing hand-carved pieces.

Recently, his main focus has been transforming ordinary pediatric medical and dental offices into extraordinarily imaginative and colorful worlds that lessen the otherwise intimidating trip to the doctor or dentist. Steve brings to life kid-friendly characters and environments, making these visits much less stressful—for everyone! Visit our Photo Gallery to see pictures of a recent jungle-themed dentist office project and visit Imagine Factory’s Facebook Page and website for an extensive portfolio of Steve’s various projects.

While pediatric medical and dental offices have been his focus in recent years, Steve has also worked with museums, creating exciting and imaginative exhibits like his Ice Castle for the Museum of Life and Science in Durham, North Carolina (also featured in our Photo Gallery). Steve is looking to do more work for amusement parks and such as well.

EPS Octopus and Submarine by Steve Morrone of Imagine Factory, LLC

EPS Octopus and Submarine by Steve Morrone of Imagine Factory, LLC ©Steve Morrone ~ Photos used with permission

Probably one of the most original and fascinating aspects of Steve’s work are his 4D murals. He starts out with a 2D painting and brings it into the realm of 4D by applying a painted EPS foam sculpture directly to the surface. This appears to be a protruding extension of the 2D world, creating an even more exciting and fantastic experience for the viewer. What makes these imaginative worlds even more special is the impeccable attention to detail and the high-quality craftsmanship that is evident at every turn. From the painting to the sculptures to the creative ideas overall, Steve Morrone and his Imagine Factory crew offer superior artistry, expertise, and workmanship that can’t be beat.

Imagine Factory has recently taken their most popular pieces and made them available to customers at standard prices. These 4D Murals© are unique handcrafted décor pieces that are now made to order. They include a sticker and a 3D foam prop that together create an exceptional dimensional piece that can enhance the charm and appeal of any room or display, including kids rooms, pediatric offices, daycares, stores, signage, play areas, you name it! Visit Imagine Factory, LLC for more information.

Inspired to start your own project? Take a look at ICA’s Product Page for your EPS foam needs.


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This article was posted on March 18, 2013, by Insulation Corporation of America (ICA) – a Women-Owned manufacturer of Geofoam and Expanded Polystyrene (EPS), which is commonly but mistakenly referred to as Styrofoam™. ICA is located in Allentown, PA and services the entire Mid-Atlantic Region from Virginia to Maine to Ohio.