Returns (channel letter returns)
Returns are the side walls of a channel letter: the strip that runs around the edge of the letter and gives it depth.
What returns are made of
Most returns are prefinished aluminum coil, bent to follow the outline of the letter's back. Some shops use steel, stainless or plastic returns for special looks. Typical values:
| Typical | |
|---|---|
| Return depth | about 3 to 5 in for front-lit letters; 5 in is very common |
| Aluminum coil thickness | about 0.040 in (also 0.032 or 0.063 in) |
| Coil width | matches the return depth, sold in long rolls |
These are typical numbers. The right depth and gauge depend on the letter size, the lighting and the local sign rules.
How returns are made
- By hand. The coil is notched and bent around the back, then riveted or glued.
- With a letter bender. An automatic bender reads the outline (usually from a DXF file) and feeds, notches and bends the coil. The outline's start point and direction matter to the machine.
The face (usually acrylic) is held on the return with trim cap, and the back (often aluminum or ACM) is attached to the other edge.
How much return material a job needs
The return length of a letter is the length of its outline: the outside edge plus the edges of any holes that get their own return. Add the outline lengths of every letter, then add a few percent for overlaps and offcuts.
How NestSigns handles it
NestSigns nests the faces and backs on your sheets and shows how many sheets the job needs, so you can price the faces and backs before you work out the return and trim cap.
Related: Channel letters · All glossary terms · Channel letter nesting · ACM nesting for letter backs
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