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Channel letters are a common sight throughout the world. The 3D graphics, bright colors, and complex designs capture customers’ attention throughout the day, and help you get the business you need. Many business owners know very little about how their signage is produced and what that means from the cost of channel letter signs overall. Let's us give you a rough ideal:

Channel Letter Sign General information

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.

How Are Channel Letter Signs Manufactured?

Channel letters consist of multiple parts that are manufactured 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.

While we weld the trim cap and face together,which is stronger.

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 1mm, 1.5mm and 3mm.

Return

On the side of every channel letter is the return. For front-lit channel letters, the return can have a depth of 2",3” or 5”, 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 may be custom-painted to match the shade of the acrylic face.