--- title: "Design Guide: Cast Metal" description: These guides are here to assist you in creating artwork that meets our specifications for your cast metal project. To quickly navigate to a specific section, click the links below.   4-inch preferred --- [Skip to content](https://hub.geminimade.com/knowledge/design-guide-cast-metal#main-content) English Show submenu for translations ![Gemini Incorporated](https://hub.geminimade.com/hubfs/gemini-logo-horizontal-1.svg) Open main navigation Close main navigation - English Show submenu for translations Try the "Ask me anything" icon at the bottom right to use our AI search - There are no suggestions because the search field is empty. 1. [Gemini Product Guide](https://hub.geminimade.com/knowledge?hsLang=en) 2. [Metal Letters and Logos](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en) 3. [Cast Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#cast-metal) September 23, 2026 # Design Guide: Cast Metal This guide is here to assist you in creating artwork that meets our minimum design specifications for your **[cast metal](https://hub.geminimade.com/knowledge/cast-metal-overview?hsLang=en)** project. To quickly navigate to a specific section, click the links below. | **[Letter Size](https://hub.geminimade.com/knowledge/design-guide-cast-metal#letter-size)** | **[Fine Point Minimum](https://hub.geminimade.com/knowledge/design-guide-cast-metal#fine-point-minimum)** | | --- | --- | | **[Minimum Serif](https://hub.geminimade.com/knowledge/design-guide-cast-metal#minimum-serif)** | [**Mounting Stroke**](https://hub.geminimade.com/knowledge/design-guide-cast-metal#mounting-stroke) | | **[Minimum Stroke](https://hub.geminimade.com/knowledge/design-guide-cast-metal#minimum-stroke)** | **[Finishing Limits](https://hub.geminimade.com/knowledge/design-guide-cast-metal#finishing-limits)** | | **[Depth Guide](https://hub.geminimade.com/knowledge/design-guide-cast-metal#depth-guide)** | **[Aluminum Size Limit](https://hub.geminimade.com/knowledge/design-guide-cast-metal#aluminum-size-limit)** | | **[Minimum Opening](https://hub.geminimade.com/knowledge/design-guide-cast-metal#minimum-opening)** | **[Polish/Buff Size Limit](https://hub.geminimade.com/knowledge/design-guide-cast-metal#polish-size-limit)** | **Tip: Need to look up a design term? [View our glossary of common terms](https://hub.geminimade.com/knowledge/geminis-signage-glossary?hsLang=en).**  --- ### Letter Size 4" to 64" sizes available. **Note:** Letters smaller than 4" will be reviewed by Gemini.  --- ### Minimum Serif | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-07-39-6937-PM.png?width=150&height=155&name=image-png-Jun-05-2023-09-07-39-6937-PM.png) | For 3/8" - 1.5" depths, **0.188" minimum serif.** | | --- | --- | **Note:** Depths larger than 1.5", need a larger serif. --- ### Minimum Stroke | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-11-25-1257-PM.png?width=150&height=143&name=image-png-Jun-05-2023-09-11-25-1257-PM.png) | For 3/8" - 1.5" depths, **0.188"** **minimum stroke**. | | --- | --- | **Note:** Depths larger than 1.5", need a larger stroke. --- ### Depth Guide Standard fonts must ONLY match standard depths: [Cast Metal Standard Fonts](https://hub.geminimade.com/knowledge/cast-metal-standard-fonts?hsLang=en) Custom fonts default to the following depths: | **Letter Height** | **Flat Face** | **Prismatic** | | --- | --- | --- | | 4" | 1/2" | 3/8" | | 5" | 3/4" | 1/2" | | 6" | 3/4" | 5/8" | | 7" | 3/4" | 5/8" | | 8" | 3/4" | 5/8" | | 9" | 3/4" | 3/4" | | 10" | 1" | 3/4" | | 12" | 1" | 3/4" | | 14" | 1" | 1" | | 15" and 16" | 1.25" | 1" | | 18" and 20" | 1.5" | 1.25" | | 22" and 24"+ | 1.5" | 1.5" | 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" minimum and 3" maximum depth --- ### Minimum Opening | ![](https://hub.geminimade.com/hubfs/image-png-Jun-05-2023-09-17-26-4703-PM.png) | For 3/8" - 1.5" depths, **0.125"** **minimum opening**. **0.188"** **for reverse cut text**. | | --- | --- | --- ### Fine Point Minimum | **![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-20-09-9075-PM.png?width=300&height=203&name=image-png-Jun-05-2023-09-20-09-9075-PM.png)** | 3/8" - 1.25" depths | 1.25" - 2.25" depths | 2.25" - 3" depths | | --- | --- | --- | --- | | **0.188"** | **0.250"** | **0.375"** | | **Note:** Fine points will be rounded or thickened for producibility. **[Contact us](https://geminimade.com/signage/support/)** with any questions regarding your artwork.  --- ### Mounting Stroke | **![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-36-42-7974-PM.png?width=250&height=188&name=image-png-Jun-05-2023-09-36-42-7974-PM.png)** | 6-32 studs | 10-24 studs | 1/4 - 20 studs | | --- | --- | --- | --- | | **0.250"** | **0.300"** | **0.500"** | | --- ### Finishing Limits | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-46-13-1724-PM.png?width=250&height=246&name=image-png-Jun-05-2023-09-46-13-1724-PM.png) | Beadblast/ Painted/ Orbital | Brushed/ Alternative Oxidized | Anodized | Patina and Oxidized | | --- | --- | --- | --- | --- | | **96" by 96"\*** | **60" by 60"** | **46.5" by 84"** | **40" by 40"** | |   **NOTE:** \*Above 60 in x 60 in requires review. --- ### Aluminum Size Limit | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-48-52-1611-PM.png?width=230&height=224&name=image-png-Jun-05-2023-09-48-52-1611-PM.png) | Bars WH402 | Letters/ Logos | Maximum | | --- | --- | --- | --- | | **8" by 48"** | **30" by 30"** | **96" by 96"\*** | |   **Note:** \*Above 60" x 60" requires review. --- ### Polish/Buff Size Limit | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-05-2023-09-50-29-0827-PM.png?width=300&height=145&name=image-png-Jun-05-2023-09-50-29-0827-PM.png) | Any depth - fits in 30" 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" are shipped with standard 10/24 studs. Thin strokes less than .3" are shipped with 6/32 studs. Cast letters 15" 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** | | | | | --- | --- | --- | --- | | | 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 **[Metal Rail Hardware Guidelines](https://hub.geminimade.com/knowledge/metal-rail-guidelines?hsLang=en)** ---   For more info on rails and other mounting hardware, check out **[our Mounting Hardware Guide](https://hub.geminimade.com/knowledge/mounting-hardware-the-foundation-behind-every-sign?hsLang=en)** 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](https://geminimade.com/signage/support/)** account. #### More About Cast Metal Letters and Logos --- **[Overview: Cast Metal](https://hub.geminimade.com/knowledge/cast-metal-overview?hsLang=en)** **[Product Specifications: Cast Metal](https://hub.geminimade.com/knowledge/cast-metal-product-specifications?hsLang=en)** **[Metal Finish Guide](https://hub.geminimade.com/knowledge/metal-finish-guide?hsLang=en)** **[Cast Metal Standard Fonts](https://hub.geminimade.com/knowledge/cast-metal-standard-fonts?hsLang=en)** **[Design Guide: Cast Metal](https://hub.geminimade.com/knowledge/design-guide-cast-metal?hsLang=en)** **[Project Examples](https://hub.geminimade.com/knowledge/cast-metal-project-examples?hsLang=en)**   - [Quote and Order Lead Times](https://hub.geminimade.com/knowledge/quote-and-order-lead-times?hsLang=en) - [Partner Portal "How-To" Articles](https://hub.geminimade.com/knowledge/partner-portal-how-to-articles?hsLang=en#main-content) - 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[Partner Resources](https://hub.geminimade.com/knowledge/partner-resources?hsLang=en#main-content) - [Partner General Resources](https://hub.geminimade.com/knowledge/partner-resources?hsLang=en#partner-general-resources) - [Partner Portal Release Notes](https://hub.geminimade.com/knowledge/partner-resources?hsLang=en#partner-portal-release-notes) - [International Partners](https://hub.geminimade.com/knowledge/partner-resources?hsLang=en#international-partners) - [Partner News](https://hub.geminimade.com/knowledge/partner-resources?hsLang=en#partner-news) - [Webinars](https://hub.geminimade.com/knowledge/partner-resources?hsLang=en#webinars) - [Plastic Letters and Logos](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en#main-content) - [Flat Cut Acrylic](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en#flat-cut-acrylic) - [Flat Cut PVC](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en#flat-cut-pvc) - [Formed Plastic](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en#formed-plastic) - [Metal Letters and Logos](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#main-content) - [Flat Cut Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#flat-cut-metal) - [Cast Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#cast-metal) - [Fabricated Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#fabricated-metal) - [Blade Signs Non-Lit](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#blade-signs-non-lit) - [Metal Finishes](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#metal-finishes) - [Laminate Letters and Logos](https://hub.geminimade.com/knowledge/laminate-letters-and-logos?hsLang=en#main-content) - [GemLeaf](https://hub.geminimade.com/knowledge/laminate-letters-and-logos?hsLang=en#gemleaf) - [Metal Laminate on Acrylic](https://hub.geminimade.com/knowledge/laminate-letters-and-logos?hsLang=en#metal-laminate-on-acrylic) - [Laminate on Foam](https://hub.geminimade.com/knowledge/laminate-letters-and-logos?hsLang=en#laminate-on-foam) - [Lit Letters and Logos](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#main-content) - [Lit Fabricated Metal Halo Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-fabricated-metal-halo-lit) - [Lit Fabricated Metal Face Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-fabricated-metal-face-lit) - [Blade Signs](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#blade-signs) - [Lit Cast Metal](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-cast-metal) - [Trimless Fabricated Metal Halo Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-fabricated-metal-halo-lit) - [Trimless Fabricated Metal Face Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-fabricated-metal-face-lit) - [Trimless Channel Face Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-channel-face-lit) - [Lit Formed Plastic](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-formed-plastic) - [Lit Acrylic Face Lit (L-100)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-face-lit-l-100) - [Lit Acrylic Face and Halo Lit (L-200)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-face-and-halo-lit-l-200) - [Lit Acrylic Face and Side Lit (L-300)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-face-and-side-lit-l-300) - [Lit Acrylic Metal Face Side Lit (L-400)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-metal-face-side-lit-l-400) - [Lit Acrylic Side Lit (L-500)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-side-lit-l-500) - [Lit Acrylic Translucent Vinyl Face And Side Lit (L-600)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-translucent-vinyl-face-and-side-lit-l-600) - [Lit Acrylic Translucent Vinyl Face Lit (L-700)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-translucent-vinyl-face-lit-l-700) - [Lit Acrylic Translucent Vinyl Face And Halo Lit (L-800)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-translucent-vinyl-face-and-halo-lit-l-800) - [Trimless Lit Acrylic Halo Lit (L-900)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-lit-acrylic-halo-lit-l-900) - [Lit Acrylic Halo Lit (L-1000)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-halo-lit-l-1000) - [Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#main-content) - [Precision Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#precision-plaques) - [Cast Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#cast-plaques) - [Etched Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#etched-plaques) - [Bronze Memorials](https://hub.geminimade.com/knowledge/plaques?hsLang=en#bronze-memorials) - [Raised Print](https://hub.geminimade.com/knowledge/plaques?hsLang=en#raised-print) - [Thin Gauge Metal Signs](https://hub.geminimade.com/knowledge/thin-gauge-metal-signs?hsLang=en#main-content) - 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