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.
Tip: Need to look up a design term? View our glossary of common terms.
Minimum Letter Size
 |
Letter Thickness | Minimum Size |
| 1/4" - 1/2" | 2" | |
| 3/4" - 1 1/2" | 3" |
Minimum Serif
 |
Letter Thickness | Minimum Serif |
| All gauges | .090" |
Minimum Stroke (for plain mounting)
 |
Minimum Size | Letter Thickness |
| 0.188" | 1/4", 3/8", and 1/2" | |
| 0.250" | 3/4", 1", and 1 1/2" |
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", and will be visible behind strokes smaller than 0.75".
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" | Thru-hole for 1/2" diameter |
| 0.53" | Thru-hole for 1" 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
| Letter Size | Studs Per Letter | Notes |
| Up to 17" | 4 studs per letter | 2 rows per letter |
| 17"-30" | 6 studs per letter | 3 rows per letter |
| Over 30" | 8 studs per letter | 4 rows per letter |
| Punctuation | 2 studs per | Where size/stroke allow |
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 |
Assembly
Plastic and metal assembly is interior only
1/4" minimum depth for top and 3/8" bottom layer for mechanical assembly using countersunk machine screws.
1/8" depth bottom layer acceptable for through hole assembly.
Tape assembly available, following standard tape restrictions.
Upcharge per piece on top layer.
Rail/Strip Mounting
Gemini does not offer acrylic letters mounted to metal rails.
Material variance can cause plastic to stress and fracture
Instead, clear plastic strips can be ordered seperately
Letters and logos mount to plastic strips via pad mounting.
Customer to provide mounting for plastic strip to installation surface.
Plastic Strip Specs
3/16"thick x 1.5"wide x 72"long
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
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