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

There are a lot of signage industry terms that are interchangeable. With channel letters, many broad terms refer to the same signage, but the components of the sign products differentiate the various styles of channel letters. Let's cover 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?

Our fabricated metal letters are channel letters without trim cap. They are dimensional letters consisting of individual plastic and metal materials assembled with optional lit inlays. Our fabricated metal letters 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 5-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 it's made easy for you to 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 channel 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

Although our fabricated metal letters are offered at a higher cost than trim cap letters, our manufacturing capabilities allow us to weld and solder metal materials to create sturdier, long-lasting letters with an emphasis on quality and longevity. We only manufacture fabricated metal letters and have several acrylic face options. They are made from premium materials and are backed by our lifetime guarantee. 

Our fabricated metal letters are an investment that offers a crisp, high-end look that portrays strength and stability and a wide range of options to achieve brand standards or the sophisticated look you want. 

5000.08