This guide is here to assist you in creating artwork that meets our minimum design specifications for a flat cut acrylic project. To quickly navigate to a specific section, click the links below.
Tip: Need to look up a design term? View our glossary of common terms.
Minimum Letter Size
 |
Letter Thickness | Minimum Size |
| 1/8" - 1/2" | 0.75" | |
| 3/4" - 1-1/2" | 2" |
Minimum Serif
 |
Minimum Size | Letter Thickness |
| 0.060" | 1/8", 3/16", and 1/4" | |
| 0.125" | 3/8" and 1/2" | |
| 0.200" | 3/4", 1", and 1 1/2" |
Minimum Stroke (for plain mounting)
 |
Minimum Size | Letter Thickness |
| 0.125" | 1/8", 3/16", and 1/4" | |
| 0.250" | 3/8", 1/2", 3/4", 1", and 1 1/2" |
Mounting Stroke
 |
0.125" | Double faced tape full coverage |
| 0.250" | Double face tape strips | |
| 0.250" | Pads | |
| 0.250" | 6-32 studs drill flush | |
| 0.300" | 10-24 studs drill flush | |
| 0.400" | GI-68 block for 6-32s | |
| 0.640" | Combo and combo all | |
| 0.640" | GI-18 block for 10-24s | |
| 1.14" | GI-14 block for 10-24s |
Note: Pads used on combination mounts are at least 0.75", and will be visible behind strokes smaller than 0.75"
Note: 1/8" - 3/16" uses Stud Blocks only.
1/4" uses Drill Flush (6-32) only. (combo mounts will use blocks)
1/2" - 1.5" uses Drill Flush only.
Minimum Opening
 |
0.020" | Unpainted, all gauges |
| 0.075" | Painted, all gauges | |
| 0.075" | Reverse cut text |
NOTE: Please refer to the Gemini Signage Glossary for the definition of "reverse cut."
Fillet Radius
 |
0.015" | Under 2" height |
| 0.025" | Between 2" - 2. 99" height | |
| 0.040" | Between 3" - 3.99" height | |
| 0.055" | Between 4" - 5.99" height | |
| 0.070" | Between 6" - 11.99" height | |
| 0.100" | Between 12" - 14.99" height | |
| 0.135" | 15" height + | |
| 0.025" | All outside corners |
NOTE: Please refer to the Gemini Signage Glossary for the definition of "fillet."
Decorative Standoffs
 |
0.41" | Thru-hole for 1/2" diameter |
| 0.53" | Thru-hole for 1" diameter |
Taping Size Limit
 |
Maximum Size | Letter Thickness |
| 30" x 30" | 1/8" | |
| 24" x 24" | 3/16" | |
| 21" x 21" | 1/4" | |
| 17" x 17" | 3/8" | |
| 15" x 15" | 1/2" | |
| 12" x 12" | 3/4" | |
| 10" x 10" | 1" and 1 1/2" |
Acrylic Size Limit
 |
24" x 24" | 1/8" |
| 30" x 30" | 3/16" | |
| 46.5" x 95" (AREA ≤ 2300 in² in one piece) | 1/4" | |
| 46.5 in x 95" (AREA ≤ 2500 in² in one piece) | 3/8", 1/2" | |
| 46.5" in x 95" (AREA ≤ 1500 in² in one piece |
3/4", 1", 1.5" |
Stud Mount Notes
1/8" and 3/16" thick receives stud blocks to receive 10-24 studs. These will not sit flush on the wall.
See details below
1/4" thick are drilled and tapped (DT) to receive a 6-32 studs (.25-.29" stroke)
3/8"+ thick receive 10-24 studs (.3 stroke)
| Letter Size | Minimum number of studs recommended |
| 1" and smaller dots and punctuation | 1 |
| 2" and smaller | 2 |
| 2-4" | 3 |
| 4-12" | 4+ |
| 12"+ | 5+ |
Studs no more than 12" apart, with a new row every 12"
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: plastic pads in line for plastic strips
Stud Blocks
GI-14 (For 10-24 studs)
Stroke of 1.14" or larger
GI-18 (for 10-24)
Stroke width of .64"-1.139"
GI-68 (for 6-32)
No combination mounting
Stroke width of .4"-.639"
Colorlast and Raised Print
Acrylic up to 1/2" thick
- Only limited by available sheet size of material and gauge.
- In some cases, we can print multiple pieces if it will fit together on the printer bed.
Hardware Limitations
- 2nd surface UV Colorlast on clear acrylic is restricted to only double-faced tape or plain for mounting options.
- Minimum 3/8" stroke required to help secure letters to the printer bed
Eased Edge
4-30" tall
1/8"-1/2" depth only
.375" stroke
.188" min opening
0.0625“ Inside Fillets - 0.025” Outside Fillets
.75" punctuation
45 degree angle cut only.
Sliders
3/8" and thicker ACRYLIC only.
Rectangles only
| Size Limits | Thickness | Min Width | Min Height | Max Width | Max Height |
| Slider Backer | 3/8” ½” ¾” 1” 1.5” | 4" | 2" | 24" | 24" |
| Slider Window | Milled .227 deep | 4" | 1.25" | 24" | 6" |
| Slider Insert | 1/8" thickness Only | 4" | .225" taller than window | 24" | .225" taller than window |
Insert must be taller than window to allow window to hold insert.
Fillet Radius
 |
.025" Outside corners Backer & Inset pieces only No Fillets on slider window No inside fillets present |
Min Distance to Edge
 |
.3" to edge |
Min. Distance between Multiple Windows
 |
Min .425" between windows
|
See the Acrylic Slider Guide for more information
Bar Size Limitations
| Tape, Plain, and Pad Mount | |||
| Depth | Max Width | Min Height | Max Height (for tape) |
| 1/8" | 48" | .25" | 18.75" |
| 3/16" | 48" | .25" | 12" |
| 1/4" | 48" | .25" | 9" |
| 3/8" | 48" | .25" | 6" |
| 1/2" | 48" | .25" | 4.6" |
| 3/4" | 48" | .375" | 3" |
| 1" | 48" | .375" | 2" |
| 1.5" | 48" | .375" | 2" |
| Stud Mount | |||
| Depth | Max Width | Min Height | Max Height |
| All | 93" | .3" | Up to sheet size limits |
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 Flat Cut Acrylic Letters and Logos
Product Overview: Flat Cut Acrylic
Product Specifications: Flat Cut Acrylic
