--- title: "Design Guide: Flat Cut Acrylic" description: These guides are here to assist you in creating artwork that meets our specifications for your flat cut acrylic project. To quickly navigate to a specific section, click the links below. --- [Skip to content](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#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. [Plastic Letters and Logos](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en) 3. [Flat Cut Acrylic](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en#flat-cut-acrylic) September 28, 2026 # Design Guide: Flat Cut Acrylic This guide is here to assist you in creating artwork that meets our minimum design specifications for a **[flat cut acrylic](https://hub.geminimade.com/knowledge/flat-cut-acrylic-overview?hsLang=en)** project. To quickly navigate to a specific section, click the links below. | **[Minimum Letter Size](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#letter-size)** | **[Fillet Radius](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#fillet)** | | --- | --- | | **[Minimum Serif](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#min-serif)** | **[Mounting Stroke](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#mounting-stroke)** | | **[Minimum Stroke](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#min-stroke)** | **[Decorative Standoffs](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#decorative-standoffs)** | | **[Minimum Opening](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#min-opening)** | **[Taping Size Limit](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#taping-size-limit)** | | **[Acrylic Size Limits](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#acrylicsizelimit)** | **[Stud Mount Notes](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#Studmountnotes)** | | **[Colorlast and Raised Print](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#Colorlast)** | **[Eased Edge](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#Eased)** | | **[Sliders](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#Sliders)** | **[Bars](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#Bar)** | | [**Assembly**](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic#Assembly) | **Weight** | **Tip: Need to look up a design term? [View our glossary of common terms](https://hub.geminimade.com/knowledge/geminis-signage-glossary?hsLang=en).** --- ### Minimum Letter Size | **![](https://hub.geminimade.com/hubfs/image-png-Jul-03-2023-07-55-11-3329-PM.png)** | **Letter Thickness** | **Minimum Size** | | --- | --- | --- | | 1/8" - 1/2" | 0.75" | | | 3/4" - 1-1/2" | 2" | | --- ### Minimum Serif | **![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jul-03-2023-07-59-16-6253-PM.png?width=150&height=171&name=image-png-Jul-03-2023-07-59-16-6253-PM.png)** | **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) | **![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jul-03-2023-08-03-00-8625-PM.png?width=150&height=142&name=image-png-Jul-03-2023-08-03-00-8625-PM.png)** | **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 | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jul-05-2023-01-52-18-8045-PM.png?width=200&height=144&name=image-png-Jul-05-2023-01-52-18-8045-PM.png) | **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 | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jul-03-2023-08-05-33-8102-PM.png?width=200&height=165&name=image-png-Jul-03-2023-08-05-33-8102-PM.png) | **0.020"** | Unpainted, all gauges | | --- | --- | --- | | **0.075"** | Painted, all gauges | | | **0.075"** | Reverse cut text | | **NOTE:** Please refer to the **[Gemini Signage Glossary](https://hub.geminimade.com/knowledge/geminis-signage-glossary?hsLang=en)** for the definition of "reverse cut." --- ### Fillet Radius | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jul-03-2023-08-12-10-0327-PM.png?width=200&height=180&name=image-png-Jul-03-2023-08-12-10-0327-PM.png) | **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](https://hub.geminimade.com/knowledge/geminis-signage-glossary?hsLang=en)** for the definition of "fillet." --- ### Decorative Standoffs | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jul-05-2023-01-56-34-8897-PM.png?width=150&height=67&name=image-png-Jul-05-2023-01-56-34-8897-PM.png) | **0.41"** | Thru-hole for 1/2" diameter | | --- | --- | --- | | **0.53"** | Thru-hole for 1" diameter | | --- ### Taping Size Limit | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jan-16-2024-07-08-11-1639-PM.png?width=213&height=63&name=image-png-Jan-16-2024-07-08-11-1639-PM.png) | **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 | ![](https://hub.geminimade.com/hubfs/image-png-Aug-10-2023-02-52-26-9829-PM.png) | 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" | **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 |   #### **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)** **![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Aug-17-2026-04-54-38-1661-PM.png?width=466&height=242&name=image-png-Aug-17-2026-04-54-38-1661-PM.png)** Stroke of 1.14" or larger **GI-18 (for 10-24)** ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Aug-17-2026-04-58-11-2785-PM.png?width=427&height=138&name=image-png-Aug-17-2026-04-58-11-2785-PM.png) Stroke width of .64"-1.139" **GI-68 (for 6-32)** **![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Aug-17-2026-04-58-56-8168-PM.png?width=440&height=106&name=image-png-Aug-17-2026-04-58-56-8168-PM.png)** No combination mounting Stroke width of .4"-.639" --- ### Colorlast and Raised Print  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 ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Aug-12-2026-06-30-59-2360-PM.png?width=283&height=280&name=image-png-Aug-12-2026-06-30-59-2360-PM.png) 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** | ![](https://hub.geminimade.com/hs-fs/hubfs/undefined-Aug-17-2026-05-30-49-3478-PM.png?width=182&height=133&name=undefined-Aug-17-2026-05-30-49-3478-PM.png) | .025" Outside corners Backer & Inset pieces only No Fillets on slider window No inside fillets present | | --- | --- | **Min Distance to Edge** | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Aug-17-2026-05-33-50-1053-PM.png?width=128&height=116&name=image-png-Aug-17-2026-05-33-50-1053-PM.png) | .3" to edge | | --- | --- | **Min. Distance between Multiple Windows** | ![](https://hub.geminimade.com/hs-fs/hubfs/image-png-Aug-17-2026-05-34-41-5464-PM.png?width=249&height=174&name=image-png-Aug-17-2026-05-34-41-5464-PM.png) | Min .425" between windows | | --- | --- | **[See the Acrylic Slider Guide](https://hub.geminimade.com/knowledge/acrylic-sliders?hsLang=en)**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 | --- ### 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. Countersunk Assembly stroke requirement: .42" for 6-32s .49" for 10-24s 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 --- ### Weight | **Thickness** | **Pounds per square inch** | | --- | --- | | 1/8" | .006 | | 3/16" | .008 | | 1/4" | .011 | | 3/8" | .017 | | 1/2" | .022 | | 3/4" | .033 | | 1" | .044 | | 1-1/2" | .066 |   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 Flat Cut Acrylic Letters and Logos --- **[Product Overview: Flat Cut Acrylic](https://hub.geminimade.com/knowledge/flat-cut-acrylic-overview?hsLang=en)** **[Product Specifications: Flat Cut Acrylic](https://hub.geminimade.com/knowledge/flat-cut-acrylic-product-specifications?hsLang=en)** **[Flat Cut Acrylic Sliders](https://hub.geminimade.com/knowledge/acrylic-sliders?hsLang=en)** **[Design Guide: Flat Cut Acrylic](https://hub.geminimade.com/knowledge/design-guide-flat-cut-acrylic?hsLang=en)** [**Project Examples: Flat Cut Acrylic**](https://hub.geminimade.com/knowledge/flat-cut-acrylic-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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[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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