---
title: "Product Specifications: Flat Cut Metal"
description: "    Flat cut metal letters and logos are available in six metal materials: Flat cut metal letters and logos can be as small as 1/2 inch up to 95 inches, depending on the metal material and finish. Let"
---

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1. [Gemini Product Guide](https://hub.geminimade.com/knowledge?hsLang=en)
2. [Metal Letters and Logos](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en)
3. [Flat Cut Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#flat-cut-metal)

September 17, 2026

# Product Specifications: Flat Cut Metal

| **[Materials](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#Materials)** | **[Size Range](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#MinMaxHeights)** |
| --- | --- |
| **[Depths](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#Depth)** | **[Fonts](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#TypefaceFonts)** |
| **[Finishes](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#Finishes)** | **[Paint](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#Paint)** |
| **[Install Environment and Cleaning](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#InstallEnvironment)** | **[Mounting and Installation](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications#MountingOptions)** |

### **Materials**

Flat cut metal letters and logos are available in six metal materials:

| [![Brushed2](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Aluminum%20Finishes/Brushed2.jpg?width=100&height=100&name=Brushed2.jpg)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Aluminum%20Finishes/Brushed2.jpg?hsLang=en) | [![Brushed 3](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Fabricated%20Metal/Brushed%203.jpg?width=100&height=100&name=Brushed%203.jpg)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Fabricated%20Metal/Brushed%203.jpg?hsLang=en) | [![Brass Alloy C464](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/Brass%20Alloy%20C464.jpg?width=100&height=99&name=Brass%20Alloy%20C464.jpg)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/Brass%20Alloy%20C464.jpg?hsLang=en) | [![Bronze Alloy](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/Bronze%20Alloy.jpg?width=100&height=100&name=Bronze%20Alloy.jpg)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/Bronze%20Alloy.jpg?hsLang=en) | [![HairlineCopper](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Fabricated%20Metal/HairlineCopper.jpg?width=94&height=99&name=HairlineCopper.jpg)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Fabricated%20Metal/HairlineCopper.jpg?hsLang=en) | [![Natrl-Rust](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Flat%20Cut%20Metal/Natrl-Rust.jpg?width=104&height=99&name=Natrl-Rust.jpg)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Flat%20Cut%20Metal/Natrl-Rust.jpg?hsLang=en) |
| --- | --- | --- | --- | --- | --- |
| **Aluminum •**Alloy 5052 | **Stainless Steel** • Alloy 304 • Alloy 316 | **Brass** • Alloy C280 | **Bronze** • Alloy C22000 | **Copper** • Alloy C11000 | **[Cor-Ten Steel](https://hub.geminimade.com/knowledge/metal-finish-guide#CorTen)** |

---

### **Size Range**

Depending on the metal material and finish, Flat Cut Metal letters and logos can be made as small as **0.75"** high up to **95"** high in a single piece. Letters and logos larger than 95" would be produced in multiple pieces.

#### **Mini Letters**

Mini letters are router cut from a solid sheet of aluminum, bronze, or brass and extend our range for Flat Cut Metal to include letters as small as **0.5"** high. Using this production method, Mini Letters can be made from **0.5" – 3"**  tall and are perfect for when small letter signs are needed.

 [![Mini Letters collage](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/MicrosoftTeams-image%20(1).png?width=357&height=250&name=MicrosoftTeams-image%20(1).png)](https://hub.geminimade.com/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/MicrosoftTeams-image%20(1).png?hsLang=en) 

For exact measurements needed for production, see the [**Design Guide**](https://hub.geminimade.com/knowledge/design-guide-flat-cut-metal?hsLang=en)

---

### **Available Depths**

| Aluminum | 1/8" | 1/4" | 3/8" | 1/2" | 3/4" | 1" |
| --- | --- | --- | --- | --- | --- | --- |
| Brass | 1/8" | 1/4" | 3/8" | 1/2" | 3/4" |  |
| Bronze | 1/8" | 1/4" | 3/8" | 1/2" |  |  |
| Copper | 1/8" | 1/4" | 3/8" |  |  |  |
| Cor-Ten | 1/8" | 1/4" |  |  |  |  |
| Stainless Steel | 1/8" | 1/4" | 3/8" | 1/2" | 3/4" |  |

General rule: the larger the letter, the thicker the material should be to prevent warping.

---

### **Fonts**

Flat cut metal signs can be made with custom fonts and vector art. We also have over ninety standard fonts if custom artwork is not required. 

**Tip: [View our standard fonts list here.](https://hub.geminimade.com/knowledge/gemini-standard-fonts?hsLang=en)** 

- Lowercase letters are 75% of the corresponding uppercase price
- Small punctuation marks, like commas, periods, and dashes are 33% of the uppercase letter price.
- For logos larger than 48 inches by 48 inches or with more than thirty-one pieces or cutouts, [**contact us through Partner Portal for a quote.**](http://www.geminimade.com/partner/)

---

### **Finishes**

We offer a variety of standard metal finishes for your made-to-order flat cut metal sign. Click on each metal material to learn more.

| ![Brushed2](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Aluminum%20Finishes/Brushed2.jpg?width=106&height=106&name=Brushed2.jpg) | ![Brushed2](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Aluminum%20Finishes/Brushed2.jpg?width=106&height=106&name=Brushed2.jpg) | ![Brass Alloy C464](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/Brass%20Alloy%20C464.jpg?width=105&height=104&name=Brass%20Alloy%20C464.jpg) | ![HairlineCopper](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Fabricated%20Metal/HairlineCopper.jpg?width=99&height=105&name=HairlineCopper.jpg) | ![Bronze Alloy](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Mini%20Flat%20Cut/Bronze%20Alloy.jpg?width=106&height=106&name=Bronze%20Alloy.jpg) | ![Natrl-Rust](https://hub.geminimade.com/hs-fs/hubfs/Gemini%20Guide%20Images/Flat%20Cut%20Metal/Natrl-Rust.jpg?width=116&height=110&name=Natrl-Rust.jpg) |
| --- | --- | --- | --- | --- | --- |
| **[Aluminum Finishes](https://hub.geminimade.com/knowledge/aluminum-finishes?hsLang=en)** | **[Stainless Steel Finishes](https://hub.geminimade.com/knowledge/stainless-steel-finishes?hsLang=en)** | **[Brass Finishes](https://hub.geminimade.com/knowledge/brass-finishes?hsLang=en)** | **[Copper Finishes](https://hub.geminimade.com/knowledge/copper-finishes?hsLang=en)** | **[Bronze Finishes](https://hub.geminimade.com/knowledge/bronze-finishes?hsLang=en)** | **[Cor-Ten Steel](https://hub.geminimade.com/knowledge/metal-finish-guide#CorTen)** |

### **Paint**

We have a selection of **48** [**standard paint colors**](https://hub.geminimade.com/knowledge/standard-paint-colors?hsLang=en) and offer custom paint matching. 

**[Textured Paint](https://hub.geminimade.com/knowledge/the-benefits-of-textured-paint?hsLang=en)** is also available for any available standard or custom color with no upcharge.

**Note:** If you are concerned about a visible metal grain, include a note in your quote or order. Additional charges may apply.

**Tip:** To learn more about our custom paint matching,**[refer to our custom colors article.](https://hub.geminimade.com/knowledge/custom-paint-colors?hsLang=en)** 

### **Colorlast and Raised Print**

This is a direct inkjet CMYK printing process. The base color is either brushed metal or painted on face and returns and then UV Printed elements are applied to the face. Finally, a clear coat seals the print.

Available on all metals with the exception of Cor-Ten, Colorlast offers a more affordable alternative to paint, without sacrificing quality.

**[Learn more here](https://hub.geminimade.com/knowledge/uv-colorlast?hsLang=en)**

### **Chamfered and Eased Edge**

Chamfered and eased edges are premium finishes only available in flat cut aluminum, bronze, brass, and copper letters 6" – 30" high.

[![Bevel](https://hub.geminimade.com/hs-fs/hubfs/BeveledAluminum.jpg?width=221&height=246&name=BeveledAluminum.jpg)](https://hub.geminimade.com/hubfs/BeveledAluminum.jpg?hsLang=en)

A **Chamfered Edge** is a type of bevel, created by using two adjacent faces to create a transitional edge. Essentially, the edge of the letter is slightly cut to add dimension.

An **Eased Edge** is a slightly rounded edge connecting two adjacent faces.

#### Chamfered Edges Notes

- Only available for letters between 6 inches - 30 inches
- Minimum of 3/8 inch thickness

#### Eased Edge Notes

- Minimum of 1/4 inch thickness

---

### **Install Environment and Cleaning**

Flat cut metal letters and logos are for interior or exterior applications.

Exterior installations may require occasional cleaning to maintain original appearance.

See our [Cleaning Guide](https://hub.geminimade.com/knowledge/letters-and-logos-cleaning-guide?hsLang=en) for more information

**Special consideration:** Coastal climates within 50 miles of the ocean should opt for anodized aluminum. Anodizing offers superior corrosion resistance in coastal climates.

**Stucco:** Stucco can cause a chemical reaction with metal letters and logos. We recommend using standoffs. This will create a gap between the material and the install surface, preventing the material from bleeding onto the surface.

---

### **Mounting and Installation**

We offer eight mounting options for flat cut metal letters and logos. Additional charges may apply.

**Note:** Every order comes with an installation pattern for a seamless installation.

| [![FCO Metal Plain](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Plain.png?width=179&height=179&name=FCO%20Metal%20Plain.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Plain.png?hsLang=en) | **Plain (No Mounts)** - No mounting holes or hardware supplied. Most metal finishes require some processing holes on letter backs, even with plain mounts. - Based on the mounting surface, some installers use double faced tape, adhesive, or a combination of the two. - Exterior applications typically require a strong adhesive and sometimes anchors to secure the letters. |
| --- | --- |
| [![FCO Metal Standard Studs-1](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Standard%20Studs-1.png?width=188&height=188&name=FCO%20Metal%20Standard%20Studs-1.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Standard%20Studs-1.png?hsLang=en) | **Stud Mount** - Letter is drilled and tapped to receive studs. - Alignment for rails, bricks, and blocks available |
| [![FCO Metal Welded Stud Boss-1](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Welded%20Stud%20Boss-1.png?width=188&height=188&name=FCO%20Metal%20Welded%20Stud%20Boss-1.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Welded%20Stud%20Boss-1.png?hsLang=en) | **Welded Stud Mount**  - 1/8" material cannot be drilled and tapped - The studs may be welded directly to the letter, or as the picture shows, a boss is welded to the letter into which the stud may thread. - **For finishes requiring this mounting (polished or anodized on 1/8", etc), Gemini will not break off the studs. Typically, standard studs with 1/4" material is recommended for such finishes.** |
| [![FCO Metal Single Rail](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Single%20Rail.png?width=188&height=188&name=FCO%20Metal%20Single%20Rail.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Single%20Rail.png?hsLang=en) | **Single Rail Mount** - Flat Or C-Channel - 25% upcharge with unfinished letter backs (standard). - 1/4" Minimum depth - Hardware to attach letters to rail provided - **Rail installation hardware not provided** |
| [![FCO Metal Double Rail](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Double%20Rail.png?width=188&height=188&name=FCO%20Metal%20Double%20Rail.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Double%20Rail.png?hsLang=en) | **Double Rail Mount** - Flat Or C-Channel - 35% upcharge with unfinished letter backs (standard). - 1/4" Minimum depth - Hardware to attach letters to rail provided - **Rail installation hardware not provided** |
| [![FCO Metal Bottom Rail2](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Bottom%20Rail2.png?width=188&height=188&name=FCO%20Metal%20Bottom%20Rail2.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Bottom%20Rail2.png?hsLang=en) | **Bottom and Top Rail Mount**   - Flat Or C-Channel - 25% upcharge with unfinished letter backs (standard). - 3/8" Minimum depth - Hardware to attach letters to rail provided - **Rail installation hardware not provided** |
| [![FCO Metal Bottom Bracket](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Bottom%20Bracket.png?width=187&height=187&name=FCO%20Metal%20Bottom%20Bracket.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Bottom%20Bracket-1.png?hsLang=en) | **Bottom Angle Bracket** - Single L shaped Bracket - 35% upcharge - Tieback recommended over 12" - 1/4" minimum depth - Hardware to attach letters to rail provided - **Rail installation hardware not provided** |
| [![FCO Metal Top and Bottom Stud](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Top%20and%20Bottom%20Stud.png?width=186&height=186&name=FCO%20Metal%20Top%20and%20Bottom%20Stud.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Top%20and%20Bottom%20Stud.png?hsLang=en) | **Bottom and Top Stud Mount**   - 15% upcharge with unfinished letter backs (standard). - 3/8" Minimum depth |
| [![FCO Metal Tape Strips](https://hub.geminimade.com/hs-fs/hubfs/FCO%20Metal%20Tape%20Strips.png?width=187&height=187&name=FCO%20Metal%20Tape%20Strips.png)](https://hub.geminimade.com/hubfs/FCO%20Metal%20Tape%20Strips.png?hsLang=en) | **Double Face Tape Mount**   - The maximum size varies by thickness and material. - **[Contact us through Partner Portal for a quote.](https://geminimade.com/partner/start-quote/)** |
| [![Thru Holes](https://hub.geminimade.com/hs-fs/hubfs/image-png-Jun-02-2025-02-17-05-1992-PM.png?width=413&height=254&name=image-png-Jun-02-2025-02-17-05-1992-PM.png)](https://hub.geminimade.com/hubfs/image-png-Jun-02-2025-02-17-05-1992-PM.png?hsLang=en) | **Thru Holes** Holes are placed at the size and location indicated on your art. No mounting hardware is provided. |
| [![Z Clips](https://hub.geminimade.com/hs-fs/hubfs/image-png-Dec-15-2025-05-04-41-9916-PM.png?width=126&height=191&name=image-png-Dec-15-2025-05-04-41-9916-PM.png)](https://hub.geminimade.com/hubfs/image-png-Dec-15-2025-05-04-41-9916-PM.png?hsLang=en) | **Z-Clips** - Also known as cleat mount |

For information on hardware requirements and restrictions, see the [Design Guide](https://hub.geminimade.com/knowledge/design-guide-flat-cut-metal?hsLang=en).

For help picking the right hardware for your job, see the [Mounting Hardware Guide](https://hub.geminimade.com/knowledge/mounting-hardware-the-foundation-behind-every-sign?hsLang=en).

---

#### More About Flat Cut Metal Letters and Logos

---

**[Overview: Flat Cut Metal](https://hub.geminimade.com/knowledge/flat-cut-metal-overview?hsLang=en)**

**[Product Specifications: Flat Cut Metal](https://hub.geminimade.com/knowledge/flat-cut-metal-product-specifications?hsLang=en)**

**[Metal Finish Guide](https://hub.geminimade.com/knowledge/metal-finish-guide?hsLang=en)**

**[Design Guide: Flat Cut Metal](https://hub.geminimade.com/knowledge/design-guide-flat-cut-metal?hsLang=en)**

**[Design Guide: Flat Cut Metal Mini Letters](https://hub.geminimade.com/knowledge/design-guide-mini-flat-cut-metal-letters?hsLang=en)**

**[Project Examples: Flat Cut Metal](https://hub.geminimade.com/knowledge/flat-cut-metal-project-examples?hsLang=en)**

- [Quote and Order Lead Times](https://hub.geminimade.com/knowledge/quote-and-order-lead-times?hsLang=en)
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    - [Flat Cut Acrylic](https://hub.geminimade.com/knowledge/plastic-letters-and-logos?hsLang=en#flat-cut-acrylic)
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- [Metal Letters and Logos](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#main-content)

    - [Flat Cut Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#flat-cut-metal)
    - [Cast Metal](https://hub.geminimade.com/knowledge/metal-letters-and-logos?hsLang=en#cast-metal)
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    - [GemLeaf](https://hub.geminimade.com/knowledge/laminate-letters-and-logos?hsLang=en#gemleaf)
    - [Metal Laminate on Acrylic](https://hub.geminimade.com/knowledge/laminate-letters-and-logos?hsLang=en#metal-laminate-on-acrylic)
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- [Lit Letters and Logos](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#main-content)

    - [Lit Fabricated Metal Halo Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-fabricated-metal-halo-lit)
    - [Lit Fabricated Metal Face Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-fabricated-metal-face-lit)
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    - [Trimless Fabricated Metal Halo Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-fabricated-metal-halo-lit)
    - [Trimless Fabricated Metal Face Lit](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-fabricated-metal-face-lit)
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    - [Lit Formed Plastic](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-formed-plastic)
    - [Lit Acrylic Face Lit (L-100)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-face-lit-l-100)
    - [Lit Acrylic Face and Halo Lit (L-200)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-face-and-halo-lit-l-200)
    - [Lit Acrylic Face and Side Lit (L-300)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-face-and-side-lit-l-300)
    - [Lit Acrylic Metal Face Side Lit (L-400)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-metal-face-side-lit-l-400)
    - [Lit Acrylic Side Lit (L-500)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-side-lit-l-500)
    - [Lit Acrylic Translucent Vinyl Face And Side Lit (L-600)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-translucent-vinyl-face-and-side-lit-l-600)
    - [Lit Acrylic Translucent Vinyl Face Lit (L-700)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-translucent-vinyl-face-lit-l-700)
    - [Lit Acrylic Translucent Vinyl Face And Halo Lit (L-800)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-translucent-vinyl-face-and-halo-lit-l-800)
    - [Trimless Lit Acrylic Halo Lit (L-900)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#trimless-lit-acrylic-halo-lit-l-900)
    - [Lit Acrylic Halo Lit (L-1000)](https://hub.geminimade.com/knowledge/lit-letters-and-logos?hsLang=en#lit-acrylic-halo-lit-l-1000)
- [Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#main-content)

    - [Precision Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#precision-plaques)
    - [Cast Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#cast-plaques)
    - [Etched Plaques](https://hub.geminimade.com/knowledge/plaques?hsLang=en#etched-plaques)
    - [Bronze Memorials](https://hub.geminimade.com/knowledge/plaques?hsLang=en#bronze-memorials)
    - [Raised Print](https://hub.geminimade.com/knowledge/plaques?hsLang=en#raised-print)
- [Thin Gauge Metal Signs](https://hub.geminimade.com/knowledge/thin-gauge-metal-signs?hsLang=en#main-content)

    - [Thin Gauge Metal Signs](https://hub.geminimade.com/knowledge/thin-gauge-metal-signs?hsLang=en#thin-gauge-metal-signs)
- [Printed Dimensional Signage](https://hub.geminimade.com/knowledge/printed-dimensional-signage?hsLang=en)
- [More Resources](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#main-content)

    - [Fonts](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#fonts)
    - [Paint](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#paint)
    - [Mounting and Installation](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#mounting-and-installation)
    - [Shipping](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#shipping)
    - [Cleaning and Maintenance](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#cleaning-and-maintenance)
    - [Warranty](https://hub.geminimade.com/knowledge/more-resources?hsLang=en#warranty)
- [Search](https://hub.geminimade.com/knowledge/search?hsLang=en)

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