This guide is here to assist you in creating artwork that meets our minimum design specifications for a flat cut metal 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 Serif
 |
All gauges: 0.080 in | |
Minimum Stroke
 |
All gauges: 0.125 in |
Minimum Sizes
 |
Smallest letter | 0.75 in |
| Smallest letters and pieces for welded studs | 3.0 in |
Minimum Opening
 |
Unpainted, all gauges | 0.050 in |
| Painted, all gauges | 0.075 in | |
| Any reverse cut text | 0.075 in |
Fillet Radius
 |
All corners when over 2 in h | 0.025 in |
| Inside corners only when under 2 in h | 0.025 in |
Mounting Stroke
 |
Double faced tape | 0.25 in |
| 6-32 studs | 0.25 in | |
| 10-24 studs | 0.300 in | |
| 1/4-20 studs | 0.500 in | |
| Welded studs | 0.500 in |
Taping Size Limit
| Aluminum | Brass, Bronze, Copper | Stainless Steel | |
| Depth |
 |
 |
 |
| 1/8" | 24"h | 14"h | 14"h |
| 1/4" | 17"h | 10"h | 9"h |
| 3/8" | 13"h | 8"h | 8"h |
| 1/2" | 12"h | 7"h | 7"h |
| 3/4" | 9"h | 5"h | n/a |
| 1" | 8"h | n/a | n/a |
Aluminum Size Limit
| Depth | Max Size | lbs/ Sq. Inch |
| 1/8" | 46.5" x 48" | .012 |
| 1/4" | 46.5" x 95" | .023 |
| 3/8" | 46.5" x 95" | .035 |
| 1/2" | 46.5" x 95" | .046 |
| 3/4" | 46.5" x 95" | .07 |
| 1" | 46.5" x 95" | .088 |
Stainless Steel Size Limit
| Depth | Max Size | lbs/ Sq. Inch |
| 1/8" | 46.5" x 48" | .012 |
| 1/4" | 46.5" x 95" | .023 |
| 3/8" | 46.5" x 95" | .035 |
| 1/2" | 46.5" x 95" | .046 |
Bronze Size Limit
| Depth | Max Size | lbs/ Sq. Inch |
| 1/8" | 35" x 95" | .04 |
| 1/4" | 45.5" x 59" | .082 |
| 3/8" | 45.5" x 59" | .126 |
| 1/2" | 45.5" x 59" | .1.64 |
Brass Size Limit
| Depth | Max Size | lbs/ Sq. Inch |
| 1/8" | 46.5" x 59" | .04 |
| 1/4" | 46.5" x 73" | .082 |
| 3/8" | 46.5" x 59" | .126 |
| 1/2" | 46.5" x 59" | .164 |
| 3/4" | 35" x 59" | .228 |
Copper Size Limit
| Depth | Max Size | lbs/ Sq. Inch |
| 1/8" | 35" x 95" | .04 |
| 1/4" | 39" x 59" | .08 |
| 3/8" | 35" x 95" | .121 |
Cor-ten Size Limit
| Depth | Max Size | lbs/ Sq. Inch |
| 1/8" | 46.5" x 95" | .03 |
| 1/4" | 46.5" x 95" | .07 |
Other Finish Limits
 |
Horizontal: 72 in w | |
 |
Vertical: 72 in h | |
 |
Anodized: 46.5 in x 84 in | |
 |
Oxidized & Patinas: 29 in x 29 in | |
Polishing Limit
 |
All gauges Must fit in 30 in circle |
|
Decorative Standoffs
 |
Thru hole for 1/2 in diameter | 0.41 in |
| Thru hole for 1 in diameter | 0.53 in |
Stud Mount Notes
1/8" metal cannot be drilled and tapped. Studs must be welded. Welded studs cannot be removed.
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.
Drilled and tapped studs available on 1/4"+ metal only.
| 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.
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 Metal Letters and Logos
Product Specifications, Mounting, and Installation
1080.10