Illuminated Letters and Logos
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Design Guide: Lit Formed Plastic

This guide is here to assist you in creating artwork that meets our minimum design specifications for your lit formed plastic 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 Stroke, Serif, and Openings

  Minimum Stroke & Serif Minimum Openings
Stepped Return 1.25 in 2 in
Flat Return 1.25 in 2 in
Faux Neon 1.25 in 2 in




Approximate Depths

Style Depth Range Available Profiles
Face & Side Lit (G-100) 2 in - 2.5 in Flat/Round/Prismatic
Halo Lit (G-200) 1.5 in - 2.5 in Flat/Round/Prismatic
Face Lit & Painted Returns (G-300) 2 in - 2.5 in Flat/Round/Prismatic
Painted Face & Lit Returns (G-400) 1.5 - 2 in Flat Face
Faux Neon (G-500) 1.5 in Round Face





Size Limit

One Piece Size Limit 45 in x 68 in




Fillet Radius

Inside Corners: 0.375 in




Raised & Painted

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




Etched & Painted

Minimum Stroke: 0.375 in





Wire Hole 0.375 in
Weep Hole 0.25 in
Cable 10 ft. long standard


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 Lit Formed Plastic 

Formed Plastic Face and Side Lit (G-100)

Formed Plastic Halo Lit (G-200)

Formed Plastic Face Lit (G-300)

Formed Plastic Side Lit (G-400)

Faux Neon Face and Side Lit (G-500)