What are Channel Letters? And What’s the Difference Between Gemini’s Fabricated Metal Letters?

Many signage industry terms are interchangeable. With channel letters, broad terms often refer to the same product—but the individual components distinguish each style. This article covers trim cap channel letters and Gemini's fabricated metal letters.

What is a channel letter? 

A channel letter is any dimensional letter composed of individually assembled plastic or metal components with optional illumination. Typical for exterior applications, channel letters are versatile and can be manufactured in various fonts, colors, and depths for extra visibility. 

With several lighting styles, channel letters can emphasize messages with face lighting, halo lighting, or a combination of two lighting styles.

Channel letters lighting styles may be referred to as

• Standard, meaning face-lit or front-lit
• Reverse, meaning halo-lit or back-lit
• Combination, meaning back and front-lit

Many channel letters are made with trim cap, a flexible plastic molding around an aluminum core. It is used with a bonding agent to secure letter faces and returns. Trim cap is malleable to the shape of a letter or logo.

Trim Cap Channel Letter	Trim Cap Channel Letter Assembly, Lit

What are Gemini fabricated metal letters?

Gemini's fabricated metal letters are channel letters constructed without trim cap. They consist of individual plastic and metal components assembled with optional lit inlays, and are made from aluminum or stainless steel alloys with optional face-lit or halo-lit lighting styles.

 

Fabricated Metal Letter, Non-lit	Fabricated Metal Letter Assembly, Non-lit

With reverse or halo-lit letters, we precision weld or solder metal faces and returns to secure the letter body. We utilize a metal outline on face lit letters and use a high-resistance epoxy to secure letter faces to the metal outline, removing the need for trim cap.

Letter backs are composed of translucent acrylic for halo-lit letters or metal backs for face-lit letters. We also supply our fabricated metal letters with an LED package with several face color options and LED color options, including a 10-year warranty on Gemini electrical components. 

Fabricated Metal Halo Lit Letter and Assembly

Fabricated Metal Face Lit Letter and Assembly

What is the difference in construction between the two?

The difference between the two is the use of trim cap. We do not manufacture trim cap channel letters, but you can easily make your own using Gemini's GemTrim, available from our distribution partners.

Trim cap creates a distinct outline, protruding from the main body of the letter. Our fabricated metal letters provide a clean, low-profile transition from the letter face to the return.

Trim Cap Channel Letter	Fabricated Metal Face Lit Letter

Trim cap channel letters are typically less durable than our fabricated metal options. If a trim cap letter has been around for a long time, it may appear dated in comparison to our fabricated metal letters. 

Trim cap channel letters are affordable. They are generally manufactured quickly at a significantly lower cost than Gemini fabricated metal letters, especially channel letters made overseas. With exposed hardware and seams at the interfaces of the trim cap and letters, there’s more opportunity for damage from the elements.

Why Choose Gemini's Fabricated Metal Letters

While Gemini's fabricated metal letters carry a higher price point than trim cap letters, our precision welding and soldering processes produce sturdier, longer-lasting signs. We manufacture only fabricated metal letters—offering multiple acrylic face options—and back every letter with our lifetime guarantee. 

Gemini's fabricated metal letters are a long-term investment that delivers a crisp, high-end appearance—projecting strength and stability—along with a wide range of customization options to meet brand standards or achieve the sophisticated look your project demands. 

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