Custom channel letters are the most popular outdoor storefront signage for shops, restaurants, offices and commercial buildings. Many overseas buyers wonder how these 3D illuminated signs are made in the factory. Here we walk you through our complete production workflow for custom channel letters.
Step 1: Artwork & Drawing Confirmation
After receiving your design files, our technical team checks the vector artwork, font size, letter thickness and mounting requirements. We make engineering drawings for production, confirm dimensions, material options and LED specifications with you. Production will only start once you approve the final drawings.
Step 2: Metal Cutting & Bending
We use stainless steel or aluminum sheet as the letter shell. The metal sheet is cut by laser cutting machine according to the drawing. Then we bend the metal to form the side return of each channel letter, weld the joints smoothly and polish the welding seams.
Step 3: Painting & Surface Finishing
The welded metal letter shells go through surface treatment. We do sandblasting, primer spraying and top coat painting. Colors can be matched to your brand color. For special requirements, brushed metal or antique metal finishes are available.
Step 4: Acrylic Face / Back Panel Preparation
For front-lit channel letters, we cut acrylic face panels to match the letter outline. For back-lit channel letters, we prepare acrylic back panels. All acrylic panels are precisely cut to fit tightly with metal letter shells.
Step 5: LED Module Installation & Wiring
We mount waterproof LED modules inside each letter cavity. LEDs are fixed on the back plate, wires are neatly routed and soldered. All internal wiring is carefully arranged to avoid short circuits. For outdoor use, we use IP65 waterproof LED modules.
Step 6: Assembly & Sealing
We assemble the acrylic panel onto the metal letter shell. Sealant is applied to the gaps to prevent water penetration. For coastal high humidity environments, extra waterproof epoxy treatment is available.
Step 7: Full Lighting Test
Every finished channel letter will go through at least 24 hours continuous lighting aging test. We check brightness, color consistency, loose wires and any lighting defects. Any defective pieces will be reworked before packing.
Step 8: Packing & Shipment
Qualified signs are cleaned and packed with foam and hard carton or wooden case. We add mounting templates and installation accessories inside the package. Then arrange shipment to your destination.
Final Words
Every custom channel letter is handcrafted with strict quality control. If you have a storefront signage project, send us your artwork for a free quotation.