Optimizing Sign Channel Letter Fabrication

CHANNEL LETTERS BOTH remote and raceway mounted still occupy the lion’s share of the current sign market. Many strip malls as well as individual storefronts wear sets of face-lit channel letters with standard 5- or 3-in. returns and trim-capped faces. Large wholesale sign companies are dedicating some or all of their capacity to manufacturing channel letters, meaning they’ve become extremely efficient at a few select processes to ensure they can produce channel letters at a cheap rate.

The prevalence of mass produced low-cost channel letters puts increased pressure on small and medium-sized sign companies to improve their channel letter fabrication to ensure they can be competitive in local and regional markets. The best way to do this is to use the latest machinery, materials and processes in their shops. Letter return-bending machines are, of course, the well-known standard for increasing channel letter productivity and are available from many different companies. However, other methods can be employed alongside these machines for maximum efficiency.

Stitching the Letter Back to the Return

The construction and general design of basic channel letters is standard and will remain mostly unchanged in the near future, but the machinery, materials and processes to make them are always evolving. One example of this evolution is the rise of the sign stitching machine, or ChannelStitcher as SDS Automation calls theirs.

This machine fastens the back of the channel letter to the return, and although many other methods can achieve this, stitching might be the fastest and most cost-effective in the long run. Channel letters can be clinched together with a clinching machine, and while this is a perfectly effective method of attaching the back to the return, clinching machines often take up a larger amount of floor space and limit the material that can be used for the backs of the letters. Other methods of attachment including adhesive or rivets can be slow, more expensive and potentially not as durable when exposed to the elements over time. The channel stitcher is fast, takes up minimal floor space, is easy to operate and allows for the possibility of using aluminum composite material (ACM) as an option for letter backs.

Less Expensive Material Options

ACM is an affordable, light, durable alternative to aluminum for letter-back material, and with companies such as Eastern Metal Supply and GSG offering American-made in-house ACM brands, the availability is comparable to aluminum sheet.

The channel stitcher does have its limitations which must be considered, mainly a limited throat depth. This means large or awkward letters could be difficult to stitch, but this can be mitigated in some instances by using a support table that works with the stitcher to hold up larger letters, as pictured.

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Trim Cap Templates

Trimming faces is another step in the channel letter fabrication process that can be improved upon to cut costs. The big debate is always between magnets and nails being the best hold-down method for trim caps when working with letter faces, but for repeat work there may be a better solution. Trim cap templates can be a valuable, one-time labor investment if you have channel letter repeat work of similar sizes. Templates can be made in your shop via many different means, similar to the way welding jigs are made. Pictured is one example of a router-cut template for use on a trimmed face. This in conjunction with an automated trim cap cutter can increase channel letter production efficiency.

New designs will become abundant as the sign industry grows, but the channel letter is here to stay. Focusing on improving your fabrication process is more important than ever to ensure competitive quotes and acceptable margins. The tips featured in this article are only a few of many that can help improve your process — various resources including the ISA International Sign Expo and other pertinent articles can help you further explore the topic of channel letter fabrication process optimization.

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