Waterjet cut from solid sheet
All our cut aluminum sign letters are cut using computer guided waterjet machines that leave the edge with a decorative frosted appearance. Cut aluminum letters are versatile and allow for virtually any shape, letter or logo to be cut with precision in thicknesses from 1/8" to 1.5". It should be said that if you need aluminum letters that are 1/2" or greater, it is far better economy to opt for Cast Aluminum Letters.
Similar to Laser cutting, Waterjets use a fine stream of water mixed with garnet under high pressure to produce intricate detail. For this reason we can cut almost any font or shape that you can imagine. The only limitation is sizes less than 1" tall as the pressure of the jet stream will bend tiny letters. If you need letters smaller than 1" then we can cut them using CNC mills. See the ordering page for Mini Metal Letters.
All cut letters come with a variety of hardware options that allow for very simple installation. For outdoor use most professional installers will choose the stud mount. By the way, when we say stud we are not referring to the studs in your wall. A stud is a length of threaded rod that screws into the back of the letter and anchors it to the wall. Double face tape is available on letters up to 6" tall but due to liability of letters falling from walls, the factory prefer you to mount heavier letters with studs. At the bottom of this page is a full list of the hardware options available and their usage. We also have videos of letter installation procedures for various mounts which cover most of our letter types. Installation Videos.
Anodized, Painted or Brushed?
Anodizing is a process where the aluminum letters are suspended in a chemical that changes the hardness of the outer aluminum layer and can impart color into the metal. The process makes the aluminum letters UV and weather safe without the need for clear coating. Anodizing does not however protect against scratching, so if you order anodized letters it is very important to protect them from damage during the installation process.
Painted Aluminum is more cost effective than anodizing and can provide letters with unlimited color variations including Sherwin Williams, PPG and Pantone shades if desired. All our letters are painted in professional automotive quality booths using wet spray. We do not offer powder coating but you can order the letters ready for powdercoat. Email for details.
Brushed and polished aluminum letters are also available in the finishes section. Polishing provides a near mirror finish, We do not offer Chrome.
The price of sheet aluminum has climbed dramatically in the past 4 years. Therefore we recommend that solid metal letters be used outdoors only. For indoor applications, our indoor display letters which are a hybrid of aluminum laminated to acrylic will provide you the same metal look at a fraction of the cost of solid metal. These hybrids indoor letters include Metal Faced Acrylic, Metal on Foam and Gemleaf.
Typically 7 to 10 production days. Products ship from closest plant to your location, Texas, Nevada, Virginia, Minnesota
The no-mount option is for when you want to glue letters directly to a flat surface using some kind of adhesive such as silicon caulk or liquid nails. The problem with this type of installation is that glue tends to squeeze out the edges and it can get very messy. Also, until your glue sets the letters can move around and for large letters that means you need to use long strips of masking tape to hold them in place.
WELDED STUD MOUNT
Only available on 1/8" material thickness. Welded studs are prone to failure and we recommend the 1/4" material option with drilled and tapped studs that are removable. A stud mount of one form or another is required when ordering Polished or Anodized letters because the manufacturing process cannot be done without them.
REMOVABLE STUD MOUNT
The most popular mount with cut metal letters is the stud mount. Aluminum letters and numbers with removable or screw in studs, have been drilled and tapped on the back of the letter to accept the stud. The stud then gets glued into your mounting surface with silicon caulk or epoxy and holds the letters firmly in place. All stud type mounts require a mounting pattern to properly locate where to drill for the studs. A stud mount of one form or another is required when ordering Polished, Anodized or Powdercoated aluminum letters because the manufacturing process cannot be done without them.
EDGE STUD MOUNT
The bottom stud (or top or both!) gives you tapped holes in the edge of the letters for mounting in a vertical configuration. Metal letters have to be at least 3/8" thick to drill the holes and the letters have a minimum height of 4" Round letters will have flat bottoms and the same applies to top drilled letters. Metal letters 8" or more must by code have tie backs when used outside. We do not supply tie backs.
BOTTOM/TOP RAIL MOUNT
Maximum length of rail is 8ft and not available for letters greater than 24" or less than 4". Metal letters are bolted through the rail into their edge and can be done either on the bottom, the top or both by request. This ordering form only provides a single rail on the bottom of the letters. For additional options please contact us for a quote.
BACK RAIL MOUNT
The double rail is mostly used for installation on metal corrugated buildings. It does detract from the look of the sign and is considered old school. In today's world a metal conduit raceway from home depot would look better to mount your letters on, and they come ready finished. Double rail mount has a maximum 8ft length and the rails are pre drilled to accept the letters ordered with screws that go through the rail into the letters. Assembly is required.
ANGLE BRACKET MOUNT
Angle bracket is mounted to a flat surface like a roof parapet and the letters are attached to the rail at the bottom only. This mount will require tie backs if outside and over 8" letter height.