Channel letter manufacturers provide an array of illuminated and non-illuminated signage. When lease agreements and local regulations allow it, channel letters can be an effective means of conveying brand identity to business customers.

Computer-driven bending and shaping machines create the characters needed for signs, including letter body depth. Aluminum sheeting may then be painted with standard colors or custom shaded according to branding-specific PMS colors.

The Face

Channel letter signage can be an incredible asset to your business, drawing customers’ eyes towards it from faraway. These 3 dimensional letters/logos designed for distance visibility make channel letter signage one of the best ways to brand your name and distinguish it.

Standard channel letters feature faces made of colored acrylic sheets cut to shape by computer numerical control routers or acrylic cutting machines, in any desired color or translucence. Clear or transparent acrylic sheets may also be available and fastened securely to their body using trim caps; trimless variants have become increasingly common over time.

Letter cans are composed of router-cut aluminum that comes in various thicknesses. Illuminated channel letters use LED illumination which is more energy efficient and cost-effective than traditional neon. Signs may either feature front or reverse/halo lighting. Front lit signs allow light to shine directly through their face for visibility in all weather conditions while reverse/halo lit signs require back lighting, creating shadowy visuals.

The Trim Cap

Channel letters are internally illuminated three-dimensional letters or logos that can be front lit, reverse lit or both for illumination. They can be installed individually, in groups or on raceways.

Faces are typically constructed of acrylic sheets that have been cut to shape using computer-controlled routers or CNC machines, depending on their color and thickness. This determines how bright or dark a letter appears, with clear or transparent faces becoming increasingly popular due to modern minimalist design trends. A trim cap usually attaches the face securely to its body for additional structural support and an attractive finishing touch on signs.

Most channel letters are installed on raceways or wireways that act both as mounting structures and electrical component containers. Some channel letters also feature back-mounted integral transformers to isolate high voltage components while minimizing holes in building facades (Fig 8). This arrangement can be particularly advantageous in historic structures with sensitive stone, marble, or granite walls.

The Body

Channel letters are constructed using router-cut aluminum sheeting that has been cut using routers, with thicknesses ranging from 0.040″ to 0.063″. The back can then be painted or shaded using standard colors or the Pantone Matching System (PMS).

Illuminated or not, the back of a sign plays an integral part of its overall aesthetic. Not only can illuminated signs spell out names or display logos for businesses to advertise them more prominently; illuminated signage also attracts passersby’s attention when passing motorists and pedestrians pass by. Most internally illuminated channel letters utilize LED lighting which offers significant energy cost savings over neon.

Aluminium returns, known as channel letter side walls, are bent using an Accu Bend machine for an attractive and long-term shape. Next, face and trim caps are adhered to these returns using an adhesive that “welds” them together into one solid piece of signage – creating a professional yet attractive sign! This method ensures a unique piece that stands out in any environment and draws customers in!

The Return

Return sides of channel letter signs, often front-lit ones, range between 3-8 inches in depth for standard front-lit signs. They must adhere to sign criteria as specified by lease agreements or city/county ordinances and computer-driven bending machines create their character using aluminum sheeting painted in standard or custom shades via PMS (Pantone Matching System).

Once returns are formed, they’re attached either by welding or fixing to a backer panel for lighting components, such as LED modules or neon gas tubes for illumination of the sign. A trim cap is added at the top of each return for aesthetic reasons and fastening purposes; depending on your type of channel letters you may also opt to leave open face without trim cap for a certain visual effect – like creating neon glow with LED tube lighting.

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