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Premium Quality
Appliques & Onlays
Decorative accents that add dimension and elegance to walls, ceilings, and facades
25+ years
expirience
5000+
projects
Custom
designs
Our Solutions Are Perfect For
From standard opening to architectural statement. Full door surround kits that transform entryways into refined architectural features - without the weight, cost, or complexity of traditional materials.
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System Architecture
EPS Core + Polyurea Shell vs. Conventional Materials
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Material Composition
Engineering Advantages of EPS/Polyurea Over Wood, PVC, and Fiberglass
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Visual Presence
Architectural Expression as an Engineering Parameter
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Durability
Systemic Service Performance of EPS/Polyurea in Demanding Climates
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Compliance
EPS/Polyurea as a Fully Documentable System
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Cost Efficiency
Total Cost of Ownership Advantage of EPS/Polyurea Over Competing Systems
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Speed of Installation
EPS/Polyurea as a Construction Schedule Compression Tool
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Customization
EPS/Polyurea Delivers Design Freedom Unavailable in Competing Systems
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Engineering
EPS/Polyurea as a Fully Designable Technical System
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Aesthetics
EPS/Polyurea as a Premium Architectural Product
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Technical specification
Door Surrounds styles
Door Surround-Door 036
Door Surround-Door 036
Door Surround-Door 042
Door Surround-Door 042
Door Surround-Door 025
Door Surround-Door 025
Door Surround-Door 023
Door Surround-Door 023
| Width (W), in | Height (H), in | Depth (D), in |
|---|---|---|
| 48" | 72" | 7" |
| 48" | 80" | 7" |
| 54" | 72" | 8" |
| 54" | 80" | 8" |
| 60" | 80" | 8 1/2" |
| 60" | 82" | 8 1/2" |
| 72" | 82" | 9" |
| 72" | 84" | 9" |
| 110" | 82" | 9 1/2" |
| 110" | 84" | 9 1/2" |
| 120" | 82" | 10" |
| 120" | 84" | 10" |
| Length (L), in | Depth (D), in | Height (H), in |
|---|---|---|
| 24" | 4" | 65" |
| 26" | 4" | 65" |
| 28" | 4" | 65" |
| 32" | 4 1/2" | 70" |
| 34" | 4 1/2" | 70" |
| 36" | 4 1/2" | 70" |
| 48" | 5" | 90" |
| 52" | 5" | 90" |
| 56" | 5" | 90" |
| 60" | 5 1/2" | 105" |
| 64" | 5 1/2" | 105" |
| 68" | 5 1/2" | 105" |
| Width (W), foot | Height (H), in | Depth (D), in |
|---|---|---|
| 10' | 8" | 7" |
| 10' | 10" | 7" |
| 12' | 8" | 8" |
| 12' | 10" | 8" |
| 14' | 8" | 8 1/2" |
| 14' | 10" | 8 1/2" |
| 16' | 8" | 9" |
| 16' | 10" | 9" |
| 18' | 12" | 9 1/2" |
| 20' | 12" | 9 1/2" |
| 24' | 12" | 10" |
| 32' | 12" | 10" |
Door Surround-Door 016
Door Surround-Door 016
Door Surround-Door 014
Door Surround-Door 014
Door Surround-Door 011
Door Surround-Door 011
Door Surround-Door 002
Door Surround-Door 002
| Width (W), in | Height (H), in | Depth (D), in |
|---|---|---|
| 48" | 72" | 7" |
| 48" | 80" | 7" |
| 54" | 72" | 8" |
| 54" | 80" | 8" |
| 60" | 80" | 8 1/2" |
| 60" | 82" | 8 1/2" |
| 72" | 82" | 9" |
| 72" | 84" | 9" |
| 110" | 82" | 9 1/2" |
| 110" | 84" | 9 1/2" |
| 120" | 82" | 10" |
| 120" | 84" | 10" |
| Length (L), in | Depth (D), in | Height (H), in |
|---|---|---|
| 24" | 4" | 65" |
| 26" | 4" | 65" |
| 28" | 4" | 65" |
| 32" | 4 1/2" | 70" |
| 34" | 4 1/2" | 70" |
| 36" | 4 1/2" | 70" |
| 48" | 5" | 90" |
| 52" | 5" | 90" |
| 56" | 5" | 90" |
| 60" | 5 1/2" | 105" |
| 64" | 5 1/2" | 105" |
| 68" | 5 1/2" | 105" |
| Width (W), foot | Height (H), in | Depth (D), in |
|---|---|---|
| 10' | 8" | 7" |
| 10' | 10" | 7" |
| 12' | 8" | 8" |
| 12' | 10" | 8" |
| 14' | 8" | 8 1/2" |
| 14' | 10" | 8 1/2" |
| 16' | 8" | 9" |
| 16' | 10" | 9" |
| 18' | 12" | 9 1/2" |
| 20' | 12" | 9 1/2" |
| 24' | 12" | 10" |
| 32' | 12" | 10" |
Door Surround-Door 036
Door Surround-Door 036
Door Surround-Door 042
Door Surround-Door 042
Door Surround-Door 025
Door Surround-Door 025
Door Surround-Door 023
Door Surround-Door 023
| Width (W), in | Height (H), in | Depth (D), in |
|---|---|---|
| 48" | 72" | 7" |
| 48" | 80" | 7" |
| 54" | 72" | 8" |
| 54" | 80" | 8" |
| 60" | 80" | 8 1/2" |
| 60" | 82" | 8 1/2" |
| 72" | 82" | 9" |
| 72" | 84" | 9" |
| 110" | 82" | 9 1/2" |
| 110" | 84" | 9 1/2" |
| 120" | 82" | 10" |
| 120" | 84" | 10" |
| Length (L), in | Depth (D), in | Height (H), in |
|---|---|---|
| 24" | 4" | 65" |
| 26" | 4" | 65" |
| 28" | 4" | 65" |
| 32" | 4 1/2" | 70" |
| 34" | 4 1/2" | 70" |
| 36" | 4 1/2" | 70" |
| 48" | 5" | 90" |
| 52" | 5" | 90" |
| 56" | 5" | 90" |
| 60" | 5 1/2" | 105" |
| 64" | 5 1/2" | 105" |
| 68" | 5 1/2" | 105" |
| Width (W), foot | Height (H), in | Depth (D), in |
|---|---|---|
| 10' | 8" | 7" |
| 10' | 10" | 7" |
| 12' | 8" | 8" |
| 12' | 10" | 8" |
| 14' | 8" | 8 1/2" |
| 14' | 10" | 8 1/2" |
| 16' | 8" | 9" |
| 16' | 10" | 9" |
| 18' | 12" | 9 1/2" |
| 20' | 12" | 9 1/2" |
| 24' | 12" | 10" |
| 32' | 12" | 10" |
Our material vs Competitors
| Property | Our Material (EPS) | Wood | Concrete | Polyurethane | Fiberglass |
|---|---|---|---|---|---|
| Weight | Very lightweight | Medium | Very heavy | Light | Light |
| Thermal Insulation | Excellent | Moderate | Poor | Excellent | Good |
| Moisture Resistance | High (does not absorb water) | Low (absorbs moisture) | Medium | High | Medium |
| Durability | Long-lasting, stable | Can rot or warp | Very durable | Durable | Fragile over time |
| Fire Behavior | Melts under high heat | Burns | Fire-resistant | Flammable (treated variants available) | Non-combustible |
| Ease of Installation | Easy, fast, low labor cost | Moderate | Difficult, labor-intensive | Moderate | Requires protection gear |
| Customization | Highly customizable shapes & sizes | Limited | Very limited | Moderate | Limited |
| Cost | Affordable | Medium to high | High | High | Medium |
We offer 9 finish types. For custom color, we have mixes that allow us to make arhitectural products in almost any color.
All textures and colors are fully customizable for each individual project, ensuring complete flexibility in design and appearance.
Each our decorative architectural foam product is unique. We don’t “print” identical beams — we craft them as individual architectural pieces.
Discuss my project
Why choose us
| Value / Service | Our company | Competitors |
|---|---|---|
| Free Design Support | ✔ Included in every project | ✖ Usually not available |
| Product Customization | ✔ Fully customized solutions | ✖ Limited options |
| Engineering Consultation | ✔ Direct access to engineers | ✖ Rare or paid |
| Unique Prototype Development | ✔ Yes, tailored prototypes | ✖ Not offered |
| Personal Project Manager | ✔ Dedicated manager for each client | ✖ Not standard |
| Speed of Production | ✔ Fast turnaround | ✖ Slower processes |
| Client Support | ✔ Ongoing support at all stages | ✖ Limited after-sales support |
| Flexibility | ✔ Tailored to any client requirements | ✖ Standard solutions only |
How it Works
Step 1. Adaptation
If you have a finished project, we adapt it for production and installation, preserving every detail.
Step 2. Define your vision
Capture a clear picture of the client’s ideas before moving to design and rendering.
Step 3. Plan specifications
Outline measurements, production methods, and finalize materials, components, and finishes.
Step 4. Installation
Our team ensures precise setup, perfectly aligning your custom surround with the space.
Step 1. Define your vision
The aim of this step is to capture a precise picture of the client’s vision before proceeding to technical design and visual rendering.
Step 2. Plan specifications
During this phase, we define the specifications, production methods, and measurements, while finalizing the look by selecting materials, elements, and finishes.
Step 3. Installation
Once fabrication is complete, our installation team will handle every aspect of the setup, ensuring your custom surround is fitted with accuracy and seamlessly integrated into your space.
Let's bring your project to life!
Door Surrounds Collection
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Original price $2,550.00 - Original price $2,550.00Original price$2,550.00$2,550.00 - $2,550.00Current price $2,550.00Door Surround-Door 050
Royal Foam USIncrease the value of your home and transform ordinary to interesting with over 100 designs, we have something to match every décor style. Door Sur...
View full detailsOriginal price $2,550.00 - Original price $2,550.00Original price$2,550.00$2,550.00 - $2,550.00Current price $2,550.00 -
Original price $1,950.00 - Original price $1,950.00Original price$1,950.00$1,950.00 - $1,950.00Current price $1,950.00Door Surround-Door 049
Royal Foam USIncrease the value of your home and transform ordinary to interesting with over 100 designs, we have something to match every décor style. Door Sur...
View full detailsOriginal price $1,950.00 - Original price $1,950.00Original price$1,950.00$1,950.00 - $1,950.00Current price $1,950.00 -
Original price $2,150.00 - Original price $2,150.00Original price$2,150.00$2,150.00 - $2,150.00Current price $2,150.00Door Surround-Door 048
Royal Foam USIncrease the value of your home and transform ordinary to interesting with over 100 designs, we have something to match every décor style. Door Sur...
View full detailsOriginal price $2,150.00 - Original price $2,150.00Original price$2,150.00$2,150.00 - $2,150.00Current price $2,150.00 -
Original price $1,950.00 - Original price $1,950.00Original price$1,950.00$1,950.00 - $1,950.00Current price $1,950.00Door Surround-Door 047
Royal Foam USIncrease the value of your home and transform ordinary to interesting with over 100 designs, we have something to match every décor style. Door Sur...
View full detailsOriginal price $1,950.00 - Original price $1,950.00Original price$1,950.00$1,950.00 - $1,950.00Current price $1,950.00 -
Original price $1,950.00 - Original price $1,950.00Original price$1,950.00$1,950.00 - $1,950.00Current price $1,950.00Door Surround-Door 046
Royal Foam USIncrease the value of your home and transform ordinary to interesting with over 100 designs, we have something to match every décor style. Door Sur...
View full detailsOriginal price $1,950.00 - Original price $1,950.00Original price$1,950.00$1,950.00 - $1,950.00Current price $1,950.00
Our Recent Works
Areas We Serve
We proudly serve clients across the United States, including major cities such as
· Jacksonville · Orlando · Miami · Atlanta · Dallas · Los Angeles · New York City · Chicago · Washington · San Francisco ·
Our Partners
Voices of our clients
I am involved in the construction and finishing of houses in Oregon, and Royal Foam's products are a great help. In particular, their door frames: they are very light and durable. This company can also create any custom design and modify the door surrounds to match any texture, whether it's plaster or wood. The latter is especially convenient because our customers often order Craftsman-style finishing details.
Jason Morrison
We used Royal Foam door casings in a Mediterranean-style villa in Southern California. The material withstands the sun and dry heat soo well! We installed them last year, and according to the customers, everything looks like new. I’d like to give a special shout-out to the Royal Foam specialists for not being afraid of complex custom tasks. We can pass on any client requests to them, and the specialist will clarify everything in detail, offer options, and even show a mock-up version before production. If only everyone worked like this, I swear!
George Powell
Everyone knows about smart homes, but how would you like a “smart door”? My husband jokingly called this way the door frames in our new house. We live in a coastal area - salty air, humidity, storms, you name it. And now, the door frames from Royal Foam have been standing up to all the challenges for almost a year. The most interesting thing is that these details look exactly like wood!
Amanda Chen
Let's bring your project to life!
Frequently Asked Questions
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They are architectural accents applied to building facades to add decorative detail, visual depth, and architectural character. People use them for keystones, medallions, dentils, frieze panels, column accents, and pediment decorations. Royal Foam US manufactures all types of these elements from expanded polystyrene with a durable polyurethane coating for maximum durability in outdoor applications.
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Yes, but only if the appropriate materials are used. EPS foam moldings with a hard polyurethane coating from Royal Foam US are fully designed for outdoor use. The expanded polystyrene core is non-hygroscopic and does not absorb moisture. The hard polyurethane coating shell is 100% waterproof, UV-resistant, and designed for the entire continental US temperature range of -40°F to +250°F.
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Royal Foam US uses EPS foam with a polystyrene foam core and a factory-applied hard polyurethane coating. EPS foam provides a lightweight, dimensionally stable interior. The durable polyurethane coating provides the impact resistance, waterproofness, and UV resistance necessary for outdoor use. This two-component system outperforms wood, cast polyurethane, and precast stone in all practical performance metrics.
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Yes. CNC machining allows us to create any profile, size, relief depth, or decorative element without the expense of mold making. Royal Foam US accepts architectural drawings, CAD files, photographs, and physical samples. Physical samples are available for approval before full-scale production of complex projects.
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Typical installation locations include window frames, doorways, columns and capitals, gables and dormers, cornices and frieze areas, exterior walls, and commercial facades.
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Royal Foam US does not use cast polyurethane as a base material. Instead, we use a polystyrene foam core with a protective rigid polyurethane shell—a technically superior system. The rigid polyurethane shell is 100% waterproof, UV-resistant, frost-resistant, and chemically resistant to external contaminants. The expected service life in outdoor applications is 25–40+ years.
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Yes. A standard EPS foam decorative molding with a hard polyurethane coating weighs 0.2–0.8 pounds. Installation requires construction adhesive and corrosion-resistant fasteners—no crane, mortar, or supporting structure is required. Installation time is 5–15 minutes per unit for an experienced installer. Royal Foam US supplies all moldings pre-finished and ready to paint, eliminating site preparation steps.
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Yes, Royal Foam US custom-machines each part from a digital CNC file. We can customize the profile, width, or relief depth to match any existing molding. Provide a sample, photograph, or cross-sectional drawing, and our team will create a matching digital molding. Physical samples are available for profile verification before mass production.
