Product Specifications: Flat Cut Metal

Materials	Size Range
Depths	Fonts
Finishes	Paint
Install Environment and Cleaning	Mounting and Installation

Materials

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


Aluminum •Alloy 5052	Stainless Steel • Alloy 304 • Alloy 316	Brass • Alloy C280	Bronze • Alloy C22000	Copper • Alloy C11000	Cor-Ten Steel

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.

For exact measurements needed for production, see the Design Guide

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.

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.

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.


Aluminum Finishes	Stainless Steel Finishes	Brass Finishes	Copper Finishes	Bronze Finishes	Cor-Ten Steel

Paint

We have a selection of 46 standard paint colors and offer custom paint matching.

Textured Paint is also available for any available standard or custom color.

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.

Colorlast and Raised Print

This is a direct inkjet CMYK printing process. The base color is 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

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.

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 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.

	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.
	Stud Mount Letter is drilled and tapped to receive studs. Alignment for rails, bricks, and blocks available
	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.
	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
	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
	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
	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
	Bottom and Top Stud Mount 15% upcharge with unfinished letter backs (standard). 3/8" Minimum depth
	Double Face Tape Mount The maximum size varies by thickness and material. Contact us through Partner Portal for a quote.
	Thru Holes Holes are placed at the size and location indicated on your art. No mounting hardware is provided.
	Z-Clips Also known as cleat mount