Channel letters are a common sight throughout America. The 3D graphics, bright colors, and complex designs capture customers’ attention throughout the day, and help you get the business you need. Yet, many business owners know very little about how their signage is produced and what that means from the cost of channel letter signs overall. By better understanding how channel letter signs are manufactured, you can shop smarter.
Channel Letter Sign Basics
If you don’t know what a channel letter sign is, then it will be difficult to imagine the fabrication process. Channel letter signs are composed of individual letters, numbers, or symbols commonly fitted with their own illumination. They are either mounted to a raceway or flush to a building. Since there is an array of customizable options, like colors, sizes, fonts, and so on, finding a professional sign company is one of the most important steps to getting quality signage.
Every element of a channel letter sign is constructed from durable yet lightweight materials, such as acrylic and aluminum, to provide durability while keeping the signage low maintenance.
What Are The Steps Involved In Creating A Channel Letter Sign?
Channel letters consist of multiple parts that are manufactured and then put together. Here is how it is done:
Face
A standard channel letter is made with an acrylic face. The acrylic sheeting is usually colored and is around 3/6” thick. The acrylic is cut into the desired shapes with either a multicam router or computer numerical control (CNC). If necessary, the colors can be customized using translucent vinyl or perforated vinyl from 3M, Oracal, Avery, or another leading manufacturer. When attaching the face to the channel letter can, it is done using something called a trim cap.
Trim Cap
The trim cap is what manufacturers use to attach the acrylic section of a channel letter to the body. The trim cap is composed of highly durable, UV-stable plastic extruded around aluminum foil. The letter face is connected to the trim cap using a bonding liquid agent that then “welds” to the acrylic, forming a watertight seal.
Backs
In a standard channel letter, the back of the section is made up of router-cut aluminum that comes in a variety of thicknesses, such as 0.040, 0.063, and 0.090.
Return
On the side of every channel letter is the return. For front-lit channel letters, the return can have a depth of 3”, 5”, or 8”, but sometimes the lease agreement for your rented store will have the exact criteria that you need to follow. Also, check local or county ordinances to see if there is a regional preference.
Returns are made of aluminum sheeting that is shaped by automated machines to fit perfectly with the face and backing of the channel letter. The aluminum can come in a number of colors or could be custom-painted to match the shade of the acrylic face.
Lighting Element
Channel letters do not have to come with LED lights, but if you do opt for illumination, it changes the manufacturing process slightly. The LED bulbs need to be painstakingly placed through the channel letter and then inspected to make sure they are up to international standards.
How Channel Letter Type Changes The Specs
Now that you know the general process surrounding the fabrication of channel letter signs, let’s consider how various sign types can affect the process:
- Front-Lit Channel Letters: Also known as standard style, the manufacturing process only changes from the above-mentioned steps if you choose non-illuminated over illuminated or vice versa. Though they can be customized in a number of ways, all front-lit channel letters have a face, trim cap, backing, and return.
- Back-Lit Channel Letters: Sometimes called reverse-lit, these channel letters are different from front-lit, where the light is emitted through the acrylic face. Instead, back-lit letters have a 0.090 aluminum face, a 0.063 aluminum return, and either a 3/16” or 1/8” poly-carbonate or Lexan backing. The return for a reverse-lit channel letter is usually shallower than a front-lit unit, averaging around 3.5” thick.
- Depending on how far these letters are mounted from the storefront, the reverse lighting can create a halo effect around the shapes. The typical distance is around 1.5” from the wall or mount.
- Combination Lit Channel Letters: For those who want the best of both channel letters, you can do a combo. In this case, a 3/16” acrylic is used for the face, and the trim cap and return are made of aluminum and are usually about 5” altogether. Similar to the reverse channel letter, the backing is also made of acrylic.
Takeaway on Channel Letter Sign Production
The manufacturing of channel letter signs is a very technical process that requires a number of materials and devices. Aluminum and acrylic are cut to exact specifications, and other elements may be necessary depending on the design. Look for sign companies that choose to use equipment like CNC, since it will lead to much more precise cuts. This ensures the channel letters are assembled correctly and will last longer.
Have questions about how channel letters are manufactured by Tupp Signs? Want to receive a quote? Give us a call or contact us by filling out the contact form.