This guide is here to assist you in creating artwork that meets our minimum design specifications for your cast metal project. To quickly navigate to a specific section, click the links below.
| Letter Size | Fine Point Minimum |
| Minimum Serif | Mounting Stroke |
| Minimum Stroke | Finishing Limits |
| Depth Guide | Aluminum Size Limit |
| Minimum Opening | Polish/Buff Size Limit |
Tip: Need to look up a design term? View our glossary of common terms.
Letter Size
4" to 64" sizes available.
Note: Letters smaller than 4 inches will be reviewed by Gemini.
Minimum Serif
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For 3/8 in - 1.5 in depths, 0.188 in minimum serif. |
Note: Depths larger than 1.5 inches, need a larger serif.
Minimum Stroke
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For 3/8 in - 1.5 in depths, 0.188 in minimum stroke. |
Note: Depths larger than 1.5 inches, need a larger stroke.
Depth Guide
Standard fonts must ONLY match standard depths: Cast Metal Standard Fonts
Custom fonts default to the following depths:
| Letter Height | Flat Face | Prismatic |
| 4 in | 1/2 in | 3/8 in |
| 5 in | 3/4 in | 1/2 in |
| 6 in | 3/4 in | 5/8 in |
| 7 in | 3/4 in | 5/8 in |
| 8 in | 3/4 in | 5/8 in |
| 9 in | 3/4 in | 3/4 in |
| 10 in | 1 in | 3/4 in |
| 12 in | 1 in | 3/4 in |
| 14 in | 1 in | 1 in |
| 15 in and 16 in | 1.25 in | 1 in |
| 18 in and 20 in | 1.5 in | 1.25 in |
| 22 in and 24 in+ | 1.5 in |
1.5 in |
3/8" min depth
3" max depth (upcharges apply above 1.5")
4" and under: Max 1" depth
4-6": Max 2" depth
Note: 3/8 inch minimum and 3 inch maximum depth
Minimum Opening
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For 3/8 in - 1.5 in depths, 0.125 in minimum opening.
0.188 in for reverse cut text. |
Fine Point Minimum
 |
3/8 in - 1.25 in depths |
1.25 in - 2.25 in depths |
2.25 in - 3 in depths |
| 0.188 in | 0.250 in | 0.375 in |
Note: Fine points will be rounded or thickened for producibility. Contact us with any questions regarding your artwork.
Mounting Stroke
 |
6-32 studs | 10-24 studs | 1/4 - 20 studs |
| 0.250 in | 0.300 in | 0.500 in |
Finishing Limits
 |
Beadblast/ Painted/ Orbital | Brushed/ Alternative Oxidized | Anodized | Patina and Oxidized |
| 96 in by 96 in* | 60 in by 60 in | 46.5 in by 84 in | 40 in by 40 in |
NOTE: *Above 60 in x 60 in requires review.
Aluminum Size Limit
 |
Bars WH402 | Letters/ Logos | Maximum |
| 8 in by 48 in |
30 in by 30 in |
96 in by 96 in* |
Note: *Above 60 in x 60 in requires review.
Polish/Buff Size Limit
 |
Any depth - fits in 30-inch circle Polished only available for cast bronze Aluminum is buffed, with slight imperfections in the face |
Profiles
| Profile | Depth | Size |
| Flat Face | 3/8"-3" | 96"X96" upon review |
| Round/Prismatic | 3/8"-3" | 46.5" x 95" upon review |
| Profile Face |
The depth of round/prismatic letters are made a 2:1 ratio of face peak vs return
Stud Mount Notes
Cast letters under 15 inches are shipped with standard 10/24 studs. Thin strokes less than .3" are shipped with 6/32 studs.
Cast letters 15 inches and up are shipped with standard 1/4-20 studs
Stud alignment options:
In line for brick: 2-5/8" on center (min 4")
In line for block: 8" on center (min 9")
In line for rail: horizontal stud alignment for rails. (Rails included at an upcharge)
Aluminum letters are supplied with aluminum studs (stainless steel studs available upon request with no extra fee).
Bronze letters are shipped with stainless steel studs.
| Hardware |
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| Part Size | Studs/Letter | Notes | |
| Up to 3"h | 3 studs min/letter | two studs in top, one in bottom | |
| 3" - 15"h | 4 studs min/letter | ||
| Over 15"h | 6 studs min/letter | ||
| Punctuation | 2 studs min/letter | where size and stroke allow | |
| Standard cast letters are drilled and tapped for a threaded stud mount. | |||
| Studs for Cast | |||
| Stud Type | Stroke | Height | Depth |
| 4-40 | <1/4" | n/a | n/a |
| 6-32 | 1/4"-3/8" | n/a | n/a |
| 10-24 | Over 3/8" | n/a | n/a |
| 1/4-20 | n/a | 15"+ | 1-1/2" and all bottom stud |
Rail Mounting Limitations
Single Rail
4-8" high
Minimum 1/4" thickness
Double Rail
8-24" high
Minimum 1/4" thickness
Bottom and/or Top Rail
4-30" high
Minimum 3/8" thickness
Over 8", tieback recommended
Bottom Angle Bracket
4-30" high
Minimum 1/4" thickness
Over 12", tieback recommended
For more info on rails and other mounting hardware, check out our Mounting Hardware Guide
All artwork is reviewed by Gemini before ordering. If modifications are required on submitted artwork, a Gemini team member will work with you to find a solution. If you have questions about your artwork, please contact us through your Partner Portal account.
More About Cast Metal Letters and Logos
Product Specifications: Cast Metal