Illuminated Sign Letters

How are channel letters made?

Channel letters are made through a meticulous fabrication process that involves several steps:

• Design: Create a design and choose the font, size, and style of the letters. This includes selecting materials like metal or plastic.
• Cutting: Cut the letter shapes from metal or acrylic sheets using computer-controlled machines like CNC routers or lasers.
• Forming: Shape the letter sides (returns) and back panels to give depth, often using bending machines.
• Assembly: Assemble the cut pieces, attaching the returns to the letter backs, and weld or bond them securely.
• Lighting: Install LED modules inside the letters, wiring them for illumination.
• Face Installation: Attach the letter faces, which can be acrylic or other translucent materials, to allow light to pass through.
• Finishing: Paint or apply finishes to the letters for the desired look.
• Testing: Test the illumination and electrical components to ensure they work correctly.
• Mounting Hardware: Attach mounting hardware like studs or raceways for easy installation.

This process results in durable, high-quality illuminated channel letters tailored to specific design and branding requirements.

What is the difference between a face lit and halo lit illuminated channel letter?

The primary difference between face lit and halo lit illuminated channel letters lies in the direction of illumination: Face Lit: These letters light up from the front face, providing bright, direct illumination. The front face is usually made of translucent acrylic, allowing the LED light to shine through. Halo Lit (Back Lit): These letters light up from the back, creating a glow or halo effect around the edges. The front of the letter remains opaque, while the back is lit, casting light onto the mounting surface. Both types offer unique visual effects, with face lit providing bold, direct visibility and halo lit offering a more subtle, elegant glow.

How long do illuminated channel letters last?

Illuminated channel letters are designed to be durable and long-lasting. With proper installation and maintenance, they typically last between 5 to 10 years or even longer. The lifespan can vary depending on factors like the quality of materials, environmental conditions, and the frequency of use. LED modules used in these letters are known for their longevity and energy efficiency, often outlasting traditional lighting sources. Additionally, many manufacturers, including Gemini, offer warranties on electrical components, which can provide further peace of mind. Regular maintenance can help ensure that the illuminated channel letters remain in optimal condition for as long as possible.

How deep are channel letters?

Channel letters come in various depths depending on their design and application. Generally, the depth of channel letters ranges from 1 inch to 6 inches. The specific depth can be customized to fit the desired look and installation requirements. For example, Gemini illuminated letters offer standard returns (the sides of the letters) from 3 inches to 6 inches. Selecting the appropriate depth ensures the letters are visible and effectively illuminated, enhancing the overall appearance of the signage.