Channel letter

A flat sheet of aluminum is typically cut on a table by a computer-controlled router, laser, or water jet, based on a vector-based art file (.cdr, .eps, .ai, .scv, .sci, or .fs).

This return can be welded at the seam or flanged and riveted or, with a metal stitcher, can be fastened with galvanized or stainless wire to the back to create a solid can in the shape of the letter.

The letter can is painted and fitted with any lighting components necessary such as neon gas tubes or light-emitting diode (LED) modules.

[1] Since the advent of LED lighting technology, channel letters have become thinner in depth, decreasing to as shallow as 2–3 in (50–80 mm) from 5–6 in (130–150 mm), a trend which began in Europe, and is seen increasingly in the United States.

This allows for the exposed neon to be seen, as well as the inside of the channel letter interior itself to add to the dimensional look.

Formed channel letters feature a molded plastic backer with a raised lip.

This light floods the wall that the letter is mounted to and creates a negative space at night.

It is thinner and broader than a raceway, and may also be used as a backer panel for the channel letter set.