This over-sized coffee cup sign was made by laminating Medex (exterior grade, dense fiberboard). This the the step where the two pieces are being cut out. There will be steel straps squeezed in-between the laminations that will allow the sign to hang straight. If you look closely you can see the slots where the steel hangers will emerge from the cup.
This was epoxied together and the edges routed with a round over bit.