Dimensional letters

Dimensional letters are solid letters cut from a flat sheet or board, such as acrylic, PVC, aluminum or HDU, and mounted on a wall or panel so they stand out with real thickness. They are not lit from inside, which sets them apart from channel letters.

Materials and thicknesses

Common materials are cast acrylic, PVC foam board, aluminum plate or composite, HDU foam and MDF or wood for indoor work. Typical thicknesses run from about 1/8 in for small lobby lettering to 1/2 in, 1 in and 2 in for bigger or bolder letters; thick letters are sometimes glued up from two layers. Indoor letters are often painted PVC or acrylic; outdoor letters are usually acrylic, aluminum or sealed HDU. These are typical choices, not rules.

How they are made

Cutting: most shops cut them on a CNC router; thin acrylic and wood are also cut on a laser. The letter outlines come from the artwork as vector paths, and counters (the holes in O, A, B, R) are cut out with each letter.
Finishing: edges are sanded or flame-polished on acrylic, and faces are painted, laminated with vinyl or left in the material's own color.
Mounting: letters are fixed flush with VHB tape and silicone, or stand off the wall on studs (pins) set into drilled holes. A paper pattern with the hole positions marked is taped to the wall to drill the holes in the right places.

Dimensional vs channel letters

Channel letters are hollow, with a back, a side return and usually a face, and LEDs inside. Dimensional letters are solid and unlit, though a halo look is possible by spacing them off a wall with lights behind. Dimensional letters cost less and are simpler to install, which is why they are common inside offices, on monument signs and on storefront panels.

How NestSigns handles it

NestSigns nests flat-cut letters by their real outlines on full sheets and on leftover pieces, keeps each letter's holes with it, puts small letters and dots inside the counters of big letters, and numbers every part so the cut letters go back into words fast. See acrylic sheet nesting and PVC letter nesting.

Try it on your own job. Open your artwork, pick a sheet, and see how many sheets you need. 20 free nesting runs, no credit card. After that, $14.99 per month, cancel anytime.
Start free