The Channel Letter Market

Channel letters are a distinct sign type and have grown in popularity since the mid-20th century.

• Illuminated channel letters require UL or similar listing and must meet installation specifications outlined in Article 600 of the National Electric Code.

• Channel letter signage is effective as advertising and identification because channel letters are easily seen and recognizable.

• Most local sign ordinances that limit square footage of commercial signage count only the actual square footage of the channel letter faces, allowing an overall larger sign presence for the business.

• Channel letters are effective at rendering logos and provide visual interest.

• Channel Letter Types

• Non-illuminated

• Illuminated with translucent plastic face

• Open-faced illuminated with exposed neon

• Reverse channel letters, non-illuminated

• Illuminated reverse channel letters (produce a halo effect)

• Channel Letter Components

• Back: The rigid material that gives the letter shape and strength.

• Returns: The sides of the letter.

• Face: Rigid surface material covering the channel letter, making a full enclosure. Face may be clear, pigmented plastic, or decorated plastic.

• Trim: Material that is wrapped around the face to secure the face to the body of the channel letter.

• Tube support: Insulated material to support neon tubing.

• Mounting hardware: Fasteners and devices used to mount the channel letter onto the mounting surface.

• Raceway: an optional separate mounting structure that also contains wiring and power supplies, resulting in fewer wall penetrations.

• Light Source: traditionally neon or fluorescent, but LEDs are becoming more widespread, except in the case of open-faced channel letters.

• Channel Letter Fabrication

• Custom one-of-a-kind channel letters have been hand made for many years using common fabrication tools and techniques.

• Aluminum is the most common channel letter material, but steel and plastic are also prevalent.

• Hand fabrication involves cutting backs and faces using: 

• Hand-held routers

• Computerized routers

• Saber saws, jigsaws and band saws

• Returns are cut from sheet metal (steel or aluminum) and formed to outline the cutout backs using:

• Shears

• Brakes

• Rollers

• Snips

• Notchers

• Backs, faces and returns of letters are assembled using:

• Rivets

• Adhesives

• Welders

• Automated Channel Letter Fabrication Products & Systems

• Automated benders, clinchers, routers, notchers, flangers, shears, brakes, trim layout systems, and fastening systems reduce labor intensive manual tasks and enable companies to produce high volumes of letters much faster, leading to a specialized channel letter wholesale marketplace.

• Automated Channel Letter System Manufacturers

• Computerized Cutters, Plano, Texas

• Arete, Denver, Colo.

• Easy Channel Letters, Lakewood, Colo.

• CLN of South Florida, Lake Worth, Fla.

• Chief Enterprises, Elmhurst, Ill.

• Channel Letter Wholesale

• Small sign companies can avoid the high capital costs associated with manufacturing by outsourcing channel letter fabrication.

• Wholesalers provide complete systems: letters, installation patterns, wiring diagrams, load calculations, power supplies, insulators, installation instructions and any other components required for a complete code-compliant installation.