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What is standard Channel Letter?

A standard channel letter is a 3 dimensional graphic sign element. Its channel is fabricated from sheet metal, most often aluminum since it will not rust. A flat sheet of aluminum is typically cut on a table by a computer-controlled router. This creates the back of the channel and is the basis for the letter shape. The sides of the channel letter, called the returns, are then formed by bending a 3 to 6-inch-wide (150 mm) strip of aluminum sheet around the aluminum back. This return can be welded at the seam or flanged and riveted to the back to create a solid can in the shape of the letter. The letter can is painted and fitted with any lighting components necessary such as neon as tubes or light-emittng diode (LED) module. A translucent plastic face usually of 3/16" thick sheet acrylic or polycarbonate is cut to fit the open face of the letter can.

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