How volumetric letters are made: stages of production

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Introduction

Channel letters are an effective and stylish way to attract attention to your brand. They are used for both outdoor and indoor advertising. The production of channel letters is a complex process that requires precision and a professional approach. In this article, we will take a detailed look at every stage of their manufacturing.

Preparation for Production

  1. Gathering client requirements
    At this stage, the client’s needs are defined, including size, design, installation location, and type of illumination (if required).
  2. Material selection
    Materials are chosen depending on operating conditions. The most popular options: acrylic, metal, plastic, wood, or their combinations.
  3. Design development
    A layout is created in specialized programs such as Adobe Illustrator or CorelDRAW for precise fabrication of components.

Main Manufacturing Stages

  1. Cutting the shape
    Blanks are cut using laser or milling equipment. This ensures precision and clean edges.
  2. Frame assembly
    The frame elements are joined together, creating a three-dimensional shape.
  3. Edge finishing
    Edges are sanded to remove irregularities and prepare for the next stages.
  4. Painting and coating
    The surface is painted or covered with vinyl film to achieve the desired look and color.
  5. Illumination installation
    If the letters are illuminated, LED strips or other light elements are installed at this stage.
  6. Final assembly
    The front panel is attached to the frame, and the finished construction is tested.

Materials for Manufacturing

  • Plastic (acrylic): lightweight, durable, and inexpensive. Often used for illuminated constructions.
  • Metal: provides a premium look and high strength. Suitable for outdoor advertising.
  • Wood: adds uniqueness and a natural touch to the design. Mostly used for interiors.
  • Combined materials: combinations of metal, plastic, and acrylic for complex constructions.

Equipment and Machinery

Modern equipment is used for the production of channel letters:

  • Laser cutters for precise shape cutting.
  • Milling machines for working with thick materials.
  • 3D printers for creating complex components.

Installation of Finished Letters

  1. Site preparation
    The surface where the letters will be installed is checked. It must be clean and level.
  2. Mounting the construction
    Letters are installed using dowels, glue, or other mounting elements, depending on the surface type.
  3. Reliability check
    Testing is carried out for stability and the operation of the illumination (if present).

Caring for Channel Letters

  • Regular cleaning from dust and dirt with a damp cloth.
  • Avoid using aggressive chemical cleaners.
  • Check the illumination and replace LED elements if necessary.

Examples of Successful Projects

  • Restaurants: stylish illuminated signs visible from afar.
  • Shopping centers: bright letters that catch customers’ attention.
  • Coworkings: modern interior letters that highlight the brand.

Advantages of Professional Manufacturing

  • Durability: high-quality materials ensure a long service life.
  • Unique design: letters can be fully personalized.
  • Time saving: professionals will quickly produce the construction according to your needs.

Conclusion

The production of channel letters is a multi-stage process that requires precision, a professional approach, and modern equipment. By entrusting the manufacturing to professionals, you receive a high-quality product that will help your business stand out among competitors.