This guide is here to assist you in creating artwork that meets our minimum design specifications for a flat cut PVC project. To quickly navigate to a specific section, click the links below.
| Minimum Letter Size | Fillet Radius |
| Minimum Serif | Mounting Stroke |
| Minimum Stroke | Decorative Standoffs |
| Minimum Opening | Taping Size Limit |
| PVC Size Limits | Bars |
Tip: Need to look up a design term? View our glossary of common terms.
Minimum Letter Size
 |
Letter Thickness | Minimum Size |
| 1/4 in - 1/2 in | 2 in | |
| 3/4-1 1/2 | 3 in |
Minimum Serif
 |
Letter Thickness | Minimum Serif |
| All gauges | .090" |
Minimum Stroke (for plain mounting)
 |
Minimum Size | Letter Thickness |
| 0.188 in | 1/4 in, 3/8 in, and 1/2 in | |
| 0.250 in | 3/4 in, 1 in, and 1 1/2 in |
Mounting Stroke
 |
Mounting Type | Minimum Stroke |
| Dbl Face Tape Strips | .250" | |
| Pads | .250" | |
| 6-32 studs drill flush | .250" | |
| 10-24 studs drill flush | .300" | |
| GI-68 block for 6-32 | .400" | |
| Combo and Combo All | .640" | |
| GI-18 block for 10-24s | .640" | |
| GI-14 block for 10-24s | 1.14" |
Note: Pads used on combination mounts are at least 0.75 inch, and will be visible behind strokes smaller than 0.75 inch.
Note:
1/4" uses Drill Flush (6-32) only. (combo mounts will use blocks)
1/2" - 1.5" uses Drill Flush only.
Minimum Opening
 |
Letter Thickness | Minimum Opening |
| 1/4" - 1/2" below 3"h | .140" | |
| 1/4" - 1/2" above 3"h | .202" | |
| 3/4" | .237" | |
| 1" and 1.5" | .270 |
NOTE: Please refer to the Gemini Signage Glossary for the definition of "reverse cut."
Fillet Radius
 |
Thickness/Location | Fillet Radius |
| 1/4" - 1/2" (inside) | .070" | |
| 3/4", 1", 1.5" (inside) | .135" | |
| Outside Regular | .025" | |
| Outside Swoosh Tips | .050" |
NOTE: Please refer to the Gemini Signage Glossary for the definition of "fillet."
Decorative Standoffs
 |
0.41 in | Thru-hole for 1/2 in diameter |
| 0.53 in | Thru-hole for 1 in diameter |
Taping Size Limit
|
|
Letter Thickness | Tape Size Limit |
| 1/4" | 28" x 28" | |
| 3/8" | 23" x 23" | |
| 1/2" | 20" x 20" | |
| 3/4" | 16" x 16" | |
| 1" | 14" x 14" | |
| 1.5" | 11" x 11" |
PVC Size Limit
 |
Size Limit |
| All thicknesses: 46.5" x 95" |
Finish Limitations
- Unpainted not offered
- Masking and painting not offered on PVC due to bleeding
- Metallic colors NOT recommended for PVC due to material porosity
Stud Mount Notes
1/4" thick are drilled and tapped (DT) to receive a 6-32 stud.
3/8"+ thick receive 10-24 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: plastic pads in line for plastic strips
Colorlast and Raised Print
PVC 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
- Minimum 3/8" stroke required to help secure letters to the printer bed
Bar Size Limitations
| Tape, Plain, and Pad Mount | |||
| Depth | Max Width | Min Height | Max Height (for tape) |
| 1/4" | 48" | .25" | 16.3" |
| 3/8" | 48" | .25" | 11" |
| 1/2" | 48" | .25" | 8.3" |
| 3/4" | 48" | .375" | 5.3" |
| 1" | 48" | .375" | 4" |
| 1.5" | 48" | .375" |
2.5" |
| 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 PVC Letters and Logos
Product Specifications, Mounting, and Installation
1010.07