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Adhesives in Sign Manufacturing

Alternative solutions to increase your sign quality and durability.

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MATERIALS IN SIGN manufacturing have changed over the years as safety has become more of a concern and as sign design has developed. The majority of signmakers are using aluminum in raw and extruded forms for the bulk of structures needed for cabinets and letters. Plastics have also been improved over the years to accommodate various lighting scenarios, but also to increase durability and usability for signmakers. As these and other materials in our industry evolve, we must explore new avenues for joining materials and holding structures together to ensure signs are both safe and cost effective.

One group of techniques seeing more popularity in the sign industry is the use of liquid and solid adhesives as the primary or back up bonding option for aluminum-to-plastic, aluminum-to-aluminum and plastic-to-plastic applications. This article will discuss a few of the many options for adhesives, which can help signshops improve manufacturing quality and efficiency.

Bolstering Your Signage’s Durability and Other Benefits

Welded channel letters both illuminated and non-illuminated are a common product in signshops. Spot welding the returns onto the letter faces or backs creates a strong bond, but as most welders know, aluminum can shear at the welds when put under stress over time. To ensure a long-lasting bond between the return and the face/back of the letter, a thin coat of construction adhesive can be applied to the seam to add an extra layer of durability to the letter.

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Applying a thin bead of construction adhesive to aluminum.


Normally, a thin bead can be applied with a calk gun and then smoothed out with a small brush to ensure the adhesive coats the surface evenly. This has an added benefit when building lighted letters as it fills small light leaks in the seam before the paint process. Many products on the market can achieve this effect, but what has been found to work best in the shop I manage is MasterWeld 948, which is a construction-grade polyurethane tack strip adhesive.

Parker LORD 406-19 Acrylic Adhesive.


Another useful construction adhesive to consider when fabricating larger structural cabinets is Parker LORD 406-19 Acrylic Adhesive. It has an extreme amount of bonding strength that has been proven to hold up as well as or better than an aluminum-to-aluminum weld, depending on the application.

Attaching an aluminum face to an angle frame.


When it comes to attaching aluminum faces to angle frames, welding is of course a viable option, but in most cases it will result in weld bumps on the outside of the sign that will give your paint department extra prep work. The Lord adhesive will eliminate these weld bumps and result in a bond that is just as durable. Keep in mind that the fumes are strong before it dries so the proper ventilation precautions and PPE must be considered before use.

Silicone Applications That Provide Extra Hold

Silicone is commonly used in all construction and building applications including signage. Chances are you already use silicone for some jobs to seal up light leaks or hold certain parts together, but there are a few other ways you can use silicone for your signage to improve its construction.

Adhesive used to secure LED modules inside a cabinet.


One way silicone can help is with keeping LED modules secured to the inside backs of cabinets and letters. Although most modules come with double-sided tape, some companies use better adhesive tapes than others. Colder temperatures or dusty conditions can also reduce the effectiveness of even the best quality double-stick tape. LED modules beginning to pop loose after installation can lead to lighting issues and subsequent repair costs, so in many cases it is worth giving yourself some extra security by using some silicone to help adhere LEDs.

Securing an acrylic backer with adhesive.


Similarly, silicone can be used to increase the security of acrylic push-throughs and poly backers in cabinets. Stud mounting push-throughs and backers are an option, but that can be more labor intensive for fab, paint prep and final assembly, depending on the sign. Weather can also play a factor in expanding and contracting plastic, which can stress the stud mounting points and cause cracking. Tape and silicone can act as an alternative for mounting plastic backers and push-throughs and can save you labor hours. Choose a silicone that is a high quality RTV brand rated for interior and exterior use, is fast drying and exhibits minimal shrinkage.

Safety and Compliance Considerations

When using any kind of chemical in your shop, safety and compliance issues must be taken into consideration. Understanding local and federal regulations on the use and disposal of chemicals in a manufacturing facility is crucial to ensure you are not hit with costly fines, or worse, a shutdown. No matter the chemicals in your shop, make sure the proper manufacturer-recommended PPE is available to all workers and is used every time. Safety Data Sheets should be up to date for every chemical used in the workplace, and all workers should know where to find them. Proper disposal methods should likewise be easily accessible and documented.

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