Cutting Techniques
FCO (Flat-Cut-Out) Letters
Flat-Cut-Out (FCO) Letters are probably the
mainstay of the architectural sign industry. These
letters can be cut out of a wide variety of materials
such as metals, plastics, composites, wood and
others. They can be dressed up with edge
treatments such as a bevel or round-over.
Engraving and 3-D Engraving
With 3-D engraving, a pointed bit is used which
leaves a V-Cut or "Chisled" bottom. This technique
allows the bit to travel out of the cuts in such a way
as to leave the corners nice and sharp. Sometimes
a combination of the two is needed as in the photo
above. If you look closely you'll see a flat bottom
with beveled edges and sharp corners.
Inlays and Push-Throughs
With Inlays, a pocket is cut into the background
material and another piece is cut to fit into the
pocket like a jigsaw puzzle piece. The inlaid piece
may fit down flush with the back or extend up
above it. What with the many different
combinations of materials, colors and techniques,
the possibilities here are endless. With Push-
Throughs, letters are cut (usually acrylic) to fit
through matching holes cut into a thin panel
(usually aluminum). The letters usually extend out
beyond the surface of the back and are often lit
from behind.
True Prismatic and Simulated
Prismatic
True Prismatic letters are way cool. But they are
also a lot of work. Simulated Prismatic letters are
also pretty cool and a lot easier to make.
Unusual Techniques
As they say, "Necessity is the mother of
invention!" Some of the challenges we've faced
have resulted in our developing new techniques.
Pictured at right are two examples of our "Folded
Aluminum" Technique.
Others include "Simulated Woodgrain", "Pebble
Texture" on Engraved Signs, Custom "Vandalized"
Finishes, "Simulated Wrought Iron" Technique
and others.