Rigid Substrate Specs and LED Hardware for Commercial Signage
This reference sheet covers the rigid sheets most sign shops work with and the hardware that goes into illuminated letters and slim light boxes. Specs are the ranges we supply; check the individual product page for what is in stock.
PVC foam board
Produced by free foam, crust foam or co-extrusion.
- Thickness: 1 mm to 30 mm
- Density: 0.33 to 0.9 g/cm³
- Crust and co-extruded boards have the harder surface and the better rigidity, which is why they are the usual choice for flatbed UV printing, structural displays and cabinetry. See PVC board.
Acrylic sheet (PMMA)
Two production routes: cast and extruded.
- Density: 1.2 g/cm³
- Thickness: 1 mm to 50 mm
- Cast acrylic has the higher molecular weight, which is what gives clean, non-yellowing edges under laser cutting and CNC engraving, plus better chemical resistance. That is why illuminated letters are usually specified in cast. See acrylic sheet.
Aluminium composite panel (ACP)
- Overall thickness: 3 mm and 4 mm
- Aluminium skin: 0.07 mm to 0.5 mm
- Polyester (PE) coating is for interior fit-out. Permanent outdoor cladding and high-level signage should be PVDF (fluorocarbon), which holds its colour and sheds dirt.
ABS double-colour sheet
- Standard sheet: 0.6 × 1.2 m, thickness 1.35 mm
- A contrasting cap layer over a base colour, engraved or laser-marked to expose the layer underneath. Used for office signage, ID badges and directional plaques where the lettering has to be sharp and permanent.
LED hardware for illuminated signage
Channel letter trim coil — 0.6 mm pre-coated or plastic-capped aluminium, and 0.4-0.7 mm stainless in brushed, mirror or electroplated finishes. The coil forms the letter body, so its gauge determines how well the housing resists wind and seals against water.
Injection LED modules — 5050, 5054 or 5730 SMD/COB chips on a 12 V DC system. The wide-angle injection lens spreads the light, which is what removes hotspots and dark patches on shallow letter faces.
LED power supplies — three ratings: indoor non-waterproof, semi-outdoor rainproof and fully glued IP67 waterproof, from 30 W to 3000 W. Match the rating to where the unit will actually sit, not to the cheapest option.
Assembly sequence
1. Form the trim coil (aluminium or steel)
2. Lay out the 12 V injection lens modules
3. Match the constant-voltage transformer to the rating required
4. Seal with structural silicone
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