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 in - 1/2 in | 0.75 in | |
| 3/4-1 1/2 | 2 in |
Minimum Serif
 |
Minimum Size | Letter Thickness |
| 0.060 in | 1/8 in, 3/16 in, and 1/4 in | |
| 0.125 in | 3/8 in and 1/2 in | |
| 0.200 in | 3/4 in, 1 in, and 1 1/2 in |
Minimum Stroke (for plain mounting)
 |
Minimum Size | Letter Thickness |
| 0.125 in | 1/8 in, 3/16 in, and 1/ 4 in | |
| 0.250 in | 3/8 in, 1/2 in, 3/4 in, 1 in, and 1 1/2 in |
Mounting Stroke
 |
0.125 in | Double faced tape full coverage |
| 0.250 in | Double face tape strips | |
| 0.250 in | Pads | |
| 0.250 in | 6-32 studs drill flush | |
| 0.300 in | 10-24 studs drill flush | |
| 0.400 in | GI-68 block for 6-32s | |
| 0.640 in | Combo and combo all | |
| 0.640 in | GI-18 block for 10-24s | |
| 1.14 in | GI-14 block for 10-24s |
Note: Pads used on combination mounts are at least 0.75 inch, and will be visible behind strokes smaller than 0.75 inch.
Note: 1/8" - 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 in | Unpainted, all gauges |
| 0.075 in | Painted, all gauges | |
| 0.075 in | Reverse cut text |
NOTE: Please refer to the Gemini Signage Glossary for the definition of "reverse cut."
Fillet Radius
 |
0.015 in | Under 2 in height |
| 0.025 in | Between 2 in - 2. 99 in height | |
| 0.040 in | Between 3 in - 3.99 in height | |
| 0.055 in | Between 4 in - 5.99 in height | |
| 0.070 in | Between 6 in - 11.99 in height | |
| 0.100 in | Between 12 in - 14.99 in height | |
| 0.135 in | 15 in height + | |
| 0.025 in | All outside corners |
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
 |
Maximum Size | Letter Thickness |
| 30 in x 30 in | 1/8 in | |
| 24 in x 24 in | 3/16 in | |
| 21 in x 21 in | 1/4 in | |
| 17 in x 17 in | 3/8 in | |
| 15 in x 15 in | 1/2 in | |
| 12 in x 12 in | 3/4 in | |
| 10 in x 10 in | 1 in and 1 1/2 in |
Acrylic Size Limit
 |
24 in x 24 in | 1/8 in |
| 30 in x 30 in | 3/16 in | |
| 46.5 in x 95 (AREA ≤ 2300 in² in one piece | 1/4 in | |
| 46.5 in x 95 (AREA ≤ 2500 in² in one piece | 3/8 in, 1/2 in | |
| 46.5 in x 95 (AREA ≤ 1500 in² in one piece |
3/4 in, 1 in, 1.5 in |
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
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
.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 |
See the Acrylic Slider Guide for more information
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