High Density Urethane (HDU) is great for making sandblasted
signs as well as many other 3 dimensional signs. It is a closed
cell rigid foam that was originally developed for the aerospace
industry.
See also
Carved HDU Signs
Routed HDU Signs
HDU Letters
now to be found in everything from nuclear submarines to the wings of modern jets to wall cavities in your home.
And as long as you keep paint on your Sandblasted HDU sign it will never deteriorate, and that's a long time.
My original sandblasted HDU house sign that is now 18 years old, was replaced with a new sandblasted HDU house sign 14 years ago. I took the old one and left it outside in full sun just to see what would happen. It was never repainted.
Absolutely NOTHING. Sandblasted HDU signs have a very low expansion - contraction factor, that means they don't move very much between heat and cold. When you couple that with the fact that they have zero moisture content, there really isn't much to go wrong.
All wooden sandblasted signs have moisture in them, when they heat up they expand, the paint can soften in the sun and when the moisture expands it can form a blister. When the cold weather comes the moisture has retracted into the sandblasted sign and the blister can crack. this channels more water into the sign and a downwards spiral is created.
So the paint simply ages gracefully. Sure the Ultra Violet sunlight will fade the paint away to nothing eventually. This is why its very important to use a good quality paint. Look at the photograph of the 18year old sandblasted HDU sign. There is hardly any paint left but there is no sign of cracking or splitting; the HDU is complete and solid.