Hi Dan, 

You mentioned that you want to fabricate these in-house - what kind of printing, mounting, and trimming tools do you have available to you? It makes a big difference as far as the processes and materials I would suggest. Though printing in-house may seem less expensive at first (could be wrong, but I'm imagining a typical office scenario with a 11x17 printer, a knife and a cutting board), sending the project to a full-service print shop often turns out to be a far better use of time and money. There are a slew of approaches you could talk to a printer about -- direct to panel, large-format inkjet mounted to sintra, applied vinyl, sandwiched plexi, or wrap-mounted gator, just to name a few combinations.

You asked about sintra -- it's a great material for exhibits. Depending on how big your labels are, you probably want to go to at least 3/16" so it's really rigid (but also difficult to cut). Another thing to keep in mind about sintra -- it's MUCH HEAVIER then foam core. So, you may need to rethink how you hang the labels on the wall, which again, figures into your overall cost analysis. 

Best of luck!
Johanna

-- 
Johanna Goldfeld Design, LLC
Graphic and Exhibition Design
Tel: 718-789-1238
Visit my website: www.jgoldfeld-design.com
Sign up for my newsletter: Pointers - Tips, ideas, and inspiration from the world of exhibition and graphic design (http://jgoldfeld-design.com/info/contact.html)

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