Flexible Face Signs Overview

Flex-face billboards like this feature a lightweight “skin” illuminated from within.

DRIVE DOWN ANY freeway and you will see them just off the road: Large signs beckoning you to stop for gas, a place to stay or something to eat. In most of the cases mentioned you are looking at flexible (a.k.a. flex) face signs. If you take a good look at one of these signs, you might think that it appears rigid as opposed to flexible. So where does that name come from?

Flexible face signs are typically constructed using a frame made of aluminum extrusion. While it is correct to assume they are constructed like a typical sign cabinet, it’s what’s on the outside that differentiates a flexible face from a typical cabinet sign. Cabinet signs, especially backlit, will use something like acrylic as a face. This works okay over a store in a strip mall or near ground level because the signs are fairly close to traffic.

Image using acrylic panels in a gas station sign that is large enough to be seen from a highway. The sign would be extremely heavy. In high-wind conditions, the acrylic would act more like a sail in that it is not porous and could easily be damaged. It is also difficult to change or renew acrylic graphics if the need arises.

Flexible face signs use a flexible PVC material in lieu of a stiff panel. You can think of it as a skin that offers a bunch of advantages. For one, the weight of the sign is significantly reduced. Graphics can be printed directly to the material, assuming you have a big enough printer. The material can be either opaque or translucent for backlit applications. The faces can be easily replaced directly on the sign frame so graphics changes or refreshes are fairly simple. The material is very resilient in high winds and won’t crack. All in all, it is an almost perfect solution.

Making flexible face signs does require some specific tools and materials. The frames are built with extruded aluminum which requires only minimal tools. You can also have frames built to your specifications. A tensioning system is built into the frame so that the face can be stretched over the frame. Specific tensioning tools are available, though in a pinch you could use a long flat-blade screwdriver. Lighting can also be added to the inside of the frame.

The material is printable with various ink technologies, such as solvent, eco-solvent and latex, and can accommodate cut vinyl. The material — either translucent or opaque media — ranges in thickness from 10 to 22 mil depending on the type and manufacturer. The media is designed for fairly extreme outdoor usage with highs of 159° down to -22° Fahrenheit.

A highway service-station sign is large so you need wide media to reduce or eliminate seams. Media rolls can be as wide as 165 in. (about 13.75 ft.) or more, so you will need a very wide printer for the biggest jobs. But you can also find media in roll sizes as narrow as 50 to 60 in. Note that if you have to work on signs larger than 13.75 ft., you will need a special welder that can join pieces together to create larger sizes.

Flexible faces make the extreme side of signmaking possible. The technology is relatively straightforward but you really need to supersize things. If you want to get into flexible face signs, make sure you have a grand format printer. If you already have the skills and equipment in house, the sky’s the limit.