Flat-cut metal letters are among the most durable and premium options in dimensional letter signage. From raw sheet metal to a finished, mounted letter, the fabrication process combines precision cutting, hand-finishing, and careful quality control. Here’s what goes into building them.

Material Selection and Cutting

We start with aluminum or stainless steel sheet in the thickness the design calls for, typically 1/4″ to 1/2″ for dimensional letters. Each letterform is cut on a CNC router or laser cutter directly from the vector artwork, which keeps every character, kerning, and radius exactly true to the approved design.

Finishing and Edge Work

After cutting, every edge is deburred and sanded smooth by hand. Depending on the look the client wants, letters are then brushed for a horizontal or swirl grain finish, polished to a mirror shine, or painted and powder-coated in a custom color. This step is what separates a professional sign shop’s letters from a generic cut piece of metal.

Mounting Hardware and Installation

Threaded studs are welded to the back of each letter in a jig to keep spacing and depth consistent, then the letters are test-fit on a template before installation. On site, we drill and anchor into the substrate and set each letter with the correct stand-off distance for a clean, level finished look.

Request a Metal Letter Fabrication Quote

Innovative Sign Systems fabricates flat-cut metal letters in-house for businesses throughout Vista, California and San Diego County. Contact our team for a quote on custom metal signage.

Flat-Cut Metal Letters FAQ