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Tip: Due to their router cutting production, Mini Letters' have different restrictions from our typical flat cut metal letters. See the Design Guide: Flat Cut Metal Mini Letters.
Minimum Serif
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0.080" |
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Minimum Stroke
 |
0.125" |
Minimum Sizes
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0.75" Smallest letter This is general rule. Producibility still largely depends on the stroke size. A letter over 0.75”h isn’t necessarily producible. 3.00" Smallest letter/piece with Welded Stud mounting This is an absolute rule. The welding equipment cannot handle pieces smaller than this. |
Minimum Opening
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0.050" Unpainted, all thicknesses 0.075" Painted, all thicknesses 0.075" An Reverse Cut Text, all thicknesses Any openings or gaps in a single letter/piece must be at least this large to produce. |
Fillet Radius
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0.025" All Corners when larger than 2"h |
Mounting Stroke
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0.250” Double Faced Tape 0.250” 6-32 studs 0.300” 10-24 studs 0.500” 1/4-20 studs 0.500” Welded Stud Letter/piece must have some areas at least this large to fit studs or tape. Tape needs a square area to fit because it is in strips. Full Coverage tape is standard on pieces 4” and below with 3/8” gauge and thinner. |
Taping Size Limit
 Aluminum |
 Brass Bronze Copper |
 Stainless Steel |
Thickness |
| 24"h | 14"h | 14"h | 1/8" |
| 17"h | 10"h | 9"h | 1/4" |
| 13"h | 8"h | 8"h | 3/8" |
| 12"h | 7"h | 7"h | 1/2" |
| 9"h | n/a | n/a | 3/4" |
| 8"h | n/a | n/a | 1" |
Size Limits and Weights
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Maximum |
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Weight |
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Maximum |
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Weight |
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Aluminum |
1/8" |
46.5" × 48" |
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0.012 |
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Brass |
1/8" |
46.5" × 59" |
0.04 |
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1/4" |
46.5" × 95" |
|
0.023 |
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1/4" |
46.5" × 73" |
0.082 |
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3/8" |
46.5" × 95" |
0.035 |
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3/8" |
46.5" × 59" |
0.126 |
|||
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1/2" |
46.5" × 95" |
0.046 |
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1/2" |
46.5" × 59" |
0.164 |
||||
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3/4" |
46.5" × 95" |
0.07 |
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3/4" |
35" × 59" |
0.228 |
||||
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1" |
46.5" × 95" |
0.088 |
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Bronze |
1/8" |
35" × 95" |
0.04 |
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Cor-Ten |
1/8" |
46.5" × 95" |
0.03 |
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1/4" |
45.5" × 59" |
0.082 |
|||
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1/4" |
46.5" × 95" |
0.07 |
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3/8" |
45.5" × 59" |
0.126 |
||||
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Stainless Steel |
1/8" |
46.5" × 48" |
0.039 |
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1/2" |
45.5" × 59" |
0.164 |
|||
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1/4" |
46.5" × 95" |
0.077 |
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Copper |
1/8" |
35" × 95" |
0.04 |
|||
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3/8" |
46.5" × 95" |
0.114 |
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1/4" |
39" × 59" |
0.08 |
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1/2" |
46.5" × 95" |
0.155 |
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3/8" |
35" × 95" |
0.121 |
Finishing Limits
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 |
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Vertical Brushed |
Horizontal Brushed |
Anodized |
Oxidized & Patinas |
Polishing Limit
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Must fit within 30" circle All thicknesses |
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Stud Mount Notes
Drilled and tapped studs are available on 1/4" or thicker material only.
The 1/8" thick metal cannot be drilled and tapped, which means any stud mounting requires welding. Welded studs are 1" long, and cannot have spacers. Welded stud bosses are optional, and can receive any length stud/spacer combination.
1/8" and 1/4" Aluminum are the same price. Due to the fragile nature of welded studs on 1/8" aluminum, 1/4" aluminum is often the preferred choice.
| Stud | Restriction |
| 6/32 | 1/4"-3/8" thick |
| 10-24 | Over 3/8" thick |
| 1/4-20 | 1/2" thick and 15"h |
| Letter Size | Minimum number of studs recommended |
| up to 3" | 3 |
| 3"-15" | 4 |
| over 15" | 6 |
| Punctuation | 2 |
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: horizontal stud alignment for rails. (Rails included at an upcharge)
Aluminum letters are supplied with aluminum studs (stainless steel studs available upon request with no extra fee).
All other metals are shipped with stainless steel studs.
Standard studs for FCO are 2" long. Other lengths available upon request.
Rail Mounting Limitations
Single Rail
4-8" high
Minimum 1/4" thickness
Double Rail
8-24" high
Minimum 1/4" thickness
Bottom and/or Top Rail
4-30" high
Minimum 3/8" thickness
Over 8", tieback recommended
Bottom Angle Bracket
4-30" high
Minimum 1/4" thickness
Over 12", tieback recommended
Colorlast and Raised Print
No welded studs for print on 1/8" material
No print on Cor-ten
No print on returns
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.