CHANGING THE CHANNEL

FEATURE NAME BY AUTHOR ACRYLICS & PLASTICS BY JANE NASH & SCOTT WALTON

Options abound for today’s channel letters.

The introduction of LED lighting modules presented numerous opportunities for sign makers, most notably enabling them the ability to design and build shallower channel letters.

LED lighting components emit little heat, which allows for closer placement of the lighting source to the channel letter sign face for a more versatile and cost-effective design.

However this particular advantage has ended up creating its own challenges. As LED modules moved closer to the surface, the light being emitted from them was centered over the source, creating hot spots of bright light. This reduced light intensity and light variations spread across the surface of the sign.

In turn, this led to new thinking about materials used in channel letters, as designers searched for solutions that transmitted and diffused light.

The objective was to maintain or increase light transmission while evenly diffusing the light across the surface— eliminating hot spots.

Sheeting Solutions This aforementioned solution allows for a shallow can and the LEDs to be as close as two inches from the interior surface of the sign face while providing the best available light transmission and diffusion.

Choosing the right grade of acrylic or polycarbonate as the face enables the use of vinyl colors over the surface

28 Sign Builder Illustrated April 2020 signshop.com Photo: Plaskolite.

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Sign Builder Illustratedis the “how-to magazine” of the sign industry. Each issue includes SBI’s signature “how-to” columns and features with detailed, step-by-step instructions covering a wide range of signage. SBI’s website (signshop. com), newsletters, Buyer’s Guide, and digital edition keep you updated with timely news, recent projects, and upcoming industry events.

The size of the letter will determine if you use acrylic or polycarbonate for its face.

minated? Or is daylight attention more important to your business? Maybe your answer is “both.”

There are techniques, using perforated vinyl, that allow signs to appear dark during the day but bright white when backlit at night.

Keep in mind that there also are new types of acrylic that achieve the same effect without using vinyl—reducing materials and cost and eliminating a step in the process.

4. Creativity Shouldn’t Be Intimidating If standard, flat channel letters aren’t enough, formed or embossed letters are possible.

To accomplish this, channel letter

without compromising transmission or diffusion.

When paired with decorative vinyl, these substrates provide designers the ability to reduce the light source—saving energy and money—while maintaining the bright, colorful appearance of the sign.

Acrylic and polycarbonate are available in a variety of colors. And with textured printing, this not only eliminates the need for vinyl, but it also enhances design options.

Here are a few things to keep in mind when considering decorative treatments for acrylic and polycarbonate used in channel letters:

1. Know Your Options for Custom Colors Some end-users require custom colors to match the logo or color palate of the signs. Acrylic and polycarbonate are available in a wide variety of industry standard colors and can match many color requests. Vinyl is another common alternative.

2. Size of the Letters Matters The size of the channel letters typically dictates the choice of polycarbonate or acrylic. Sign industry standards call for polycarbonate if the faces are more than thirty-six inches tall. At that size, it’s a safety concern.

Acrylic letters larger than three feet are difficult to manipulate and transport and run a higher risk of breaking. Polycarbonate is virtually unbreakable and so is suitable for larger letters.

3. Day, Night, or Both? There are questions that you need to ask yourself: Do you want the channel letter sign to pop at night, when illu

TENTS, FLAGS, SIGNS & MORE

designers take a sheet of acrylic or polycarbonate, heat it, and use a mold to fashion the thermoplastic sheet into the desired design.

After heating, a vacuum is applied to draw down the acrylic or polycarbonate on to the mold.

After it has finished cooling, the product will retain the shape of the mold, giving it a 3-D look.

5. Remember Fabrication, Installation, and Durability In addition to pure acrylic, an impactmodified sheet with rubber particles added to the resin during manufacturing provides an impact- and breakresistant quality. The end-result is a

Acrylic letters made from impact-modified sheets are easier to cut and fabricate.

EXPANSIVE RANGE OF OUTDOOR DISPLAYS FOR EVENTS & ADVERTISING

signshop.com sheet that doesn’t break as easily as normal acrylic.

Acrylic letters made from impactmodified sheets are easier to cut, fabricate, and handle without cracking during delivery from the shop.

Polycarbonate is also an excellent choice in sign applications. It delivers impact, as well as temperature and weather resistance.

When thermoformed, a polycarbonate material adds dimension to enhance logos and letters. Thinner deep draw areas retain strength.

Polycarbonate meets the UL879 standard for use in electrical signs. In addition, polycarbonate has a UL flammability rating. Be sure to contact the manufacturer listed.

Conclusion: The Bottom Line The pairing of LED lights with acrylic and polycarbonate channel letters offers exciting alternatives in sign design and construction.

The good news is that today there are more product choices than ever before, as well as enhanced capabilities that are related to custom colors and textured surfaces. Businesses should consider all options available to them when making a statement with their channel letter signage. Acrylic and polycarbonate sheet products offer performance that protects the image.

Jane Nash is sales development specification and Scott Walton is southeast territory manager at Plaskolite (plaskolite. com), of Columbus, Ohio. The manufacturer oers high-performance polymers and thermoplastic sheet products including OPTIX LD (Light Diusing) acrylic and TUFFAK LD polycarbonate.

April 2020 Sign Builder Illustrated 31 Photo: Dave Forrest.