Our Shop Teams
Letter Fabrication
Letter Fabrication is one of the first steps in the signage process that creates the framework of the letters. Our team in the Letter Fabrication Department brings a design to life through the Computer Numerical Control (CNC) Router and SDS Channel Letter Machine, which creates the three-dimensional letter shapes. The machines form, fit, and fasten the letter backs and sides together by drilling, riveting, stapling, or welding. The CNC Router has streamlined the process of creating letters by producing them at a faster pace and yielding more efficient results.
Metal Fabrication
Metal Fabrication is an essential step in the signage process that produces critical signage components. Our team in the Metal Fabrication Department uses various hand and power tools such as bandsaws, drills, torches, welding machines, pipe, and angle rollers, CNC forming machines, aluminum extrusion saws, and more to process raw materials in various assemblies and sub-assemblies, which include routing, bending, shaping, and drilling raw material. These are used to fabricate many sign components to help bring the sign to life.
Computer Numerical Control - CNC Router
A CNC Router is a computer-controlled machine mounted on a large router table ran by CAD software. After the software calculates the cutting instructions, it can move in three dimensions and automatically cut out the parts needed for a sign. It gives us the ability to create highly accurate designs and letters and has led to new styles of signs that weren't possible before its development. CNC Routers can work with a wide variety of sign-making materials such as acrylic, sign-foam, aluminum, other light materials, hardwood, plywood, and wood composites, Lexan (a polycarbonate resin thermoplastic). Our team that works with the CNC Routers is essential to our sign-making process, turning a 2D drawing into a 3D sign.
Vinyl
Our Vinyl Department is an integral part of our signage process; they work with their hands to prepare and install vinyl graphics. The designs are created, cut files are made, and sent to the vinyl plotter, which cuts out the designs. The vinyl is then applied to where it is needed to create the individual sign or LOGO. We use vinyl because it is resistant to moisture and humidity, strong and durable, and environmentally friendly.
Paint
Our Paint Department adds vibrant color and ensures that our client's signs are branded perfectly. Before they begin painting, every aluminum item is given an acid bath to remove residual oils and other residues that would repel the finish. After the wash, surfaces that will be painted are sanded or scuffed. Body filler is used to fix dents before moving to the heated paint booth. The heated paint booth provides a better spraying environment, allowing for a better finish.
Assembly
Our Assembly Department pulls everything together to make the sign “come to life.” All the necessary parts and pieces are brought to the Assembly Department and sorted out accordingly. Next, all the electrical components are installed to UL Standards, powered up, and checked for correct function. Our team then attaches the UL label and prepares the signs for shipping.
Shipping
The Shipping Department ensures that our client's signs make it to the correct location as efficiently and safely as possible. They gather the parts for each sign package and prepare them for shipment. Building a custom crate for each unit, to ensure there is no damage during transit. They set up transportation to sign shops and installation locations all over the country. We have shipped from South Carolina to places as far as California, Canada, Mexico, and even Hawaii.
Interior
Our Interior Department produces the signage inside our client’s project and ensures it is perfect for their branding. After the Design and CAD Departments approve our client’s artwork, the Interior Department manufactures plaques, directional, and instructional signs. All while following compliance with the Americans with Disabilities Act (ADA) that requires handicap accessible signs and braille. The Raster®Braille Pen is used to insert raster spheres into pre-drilled holes to create braille signs.
Sometimes, the CNC Routers aren’t exact enough because they cannot cut smaller than the bits allow. Some of the smaller parts can be cut for the Assembly Department utilizing a laser engraver/cutter for custom designs.
When 3rd party signs require repair or replacement, the department uses a digitizer to replicate a sign into a tracing. A digitizer is a board that can send XY points to a computer and works when using the pen stylus to trace over the pattern. The design is vectorized and sent to the CAD Department to build a router file which can then be used to reproduce the original part for the sign.