Design Guide: Formed Plastic

This guide is here to assist you in creating artwork that meets our minimum design specifications for a formed plastic project. To quickly navigate to a specific section, click the links below.

Minimum Serif	Minimum Stroke
Minimum Prismatic Face Serif	Minimum Opening
Mounting Stroke	Flanges
Raised & Painted	Etched & Painted
Size Limit	Letter Depth

Tip: Need to look up a design term? View our glossary of common terms.

Note: Minimum space between individual letters and/or pieces is 0.3 inches.

Minimum Flat Face and Round Face Serif

ACRY (Pigmented)

	6 in - 8.9 in	0.31 in
	9 in - 14.9 in	0.44 in
	15 in - 23.9.9 in	0.5 in
	24 in - 36 in	0.56 in

CAB

	4 in - 8.9 in	0.375 in
	9 in - 14.9 in	0.5 in
	15 in - 17.9 in	0.63 in
	18 in - 36 in	0.75 in

Note: If you have questions about your artwork, contact us through your Partner Portal account.

Minimum Prismatic Face Serif

Letter Height	Minimum Size
4" -9.9"	0.400 in
10" - 14.9"	0.500 in
15" - 29.9"	0.630 in
30 in +	1 in

Minimum Stroke for Plain Mount

ACRY

	6 in - 8.9 in	0.5 in
	9 in - 14.9 in	0.625 in
	15 in - 23.9 in	0.75 in
	24 in - 36 in	0.75 in

CAB

	4 in - 8.9 in	0.5 in
	9 in - 14.9 in	0.63 in
	15 in - 17.9 in	0.7 in
	18 in - 36 in	0.75 in

Minimum Opening

ACRY

	6 in - 8.9 in	0.75 in
	9 in - 14.9 in	1 in
	15 in - 23.9 in	1.25 in
	24 in - 36 in	1.5 in

CAB

	4 in - 8.9 in	0.5 in
	9 in - 14.9 in	1 in
	15 in - 17.9 in	1.25 in
	18 in - 36 in	1.5 in

Minimum Mounting Stroke

	Stud Blocks	0.750 in
	Pads	0.750 in
	Studs with Pads	0.750 in

Flanges

Standard Size: 0.375 in

Available in:

1/16", 1/8", 1/4" 3/8", 1/2" 5/8", 3/4" 1"

Raised & Painted

Min Serif	Min Stroke	Raised Depth	Min Opening
0.25 in	0.375 in	0.25 in	0.5 in
0.375 in	0.5 in	0.5 in	0.625 in
0.5 in	0.5 in	0.75 in	0.75 in

Etched & Painted

Minimum Stroke: 0.375 in

Formed Size Limit

			One piece: 45 in x 68 in
			Two pieces: 45 in x 136 in
			Two pieces: 90 in x 68 in

Note: Visible non-squared seam. Will not join flush.

Letter Depths

Acry

Letter Size	Approximate Finished Depth
6 inch - 8.9 inch	1/2 inch
9 inch - 14.9 inch	3/4 inch
15 inch - 23.9 inch	1 inch
24 inch - 36 inch	1.25 inch
Cab

Letter Size	Approximate Finished Depth
6 inch - 8.9 inch	1/2 inch
9 inch - 14.9 inch	3/4 inch
15 inch - 17.9 inch	1 inch
18 inch - 36 inch	1.25 inch
Deeper depths available upon request. Deepest standard finished depth is 1.25 inches. Any depth between 1.5 inch and 2.75 inch by request only and with added cost. One step up in depth allowed only! Example: 7" letter is 1/2" depth. Max is 3/4". 1" must be reviewed, but is unlikely.

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 Formed Plastic Letters and Logos

Product Overview

Product Specifications, Mounting, and Installation

Project Examples

Pricing

Product Warranty

Formed Plastic Letter-Standard Fonts

1020.08