Home > Cutting Techniques

Cutting Techniques

 FCO  (Flat-Cut-Out)  Letters

Flat-Cut-Out (FCO) Letters are probably the mainstay of the architectural sign industry.  These letters can be cut out of a wide variety of materials such as metals, plastics, composites, wood and others.  Of course, just because they are "Flat-Cut-Out" doesn't mean they have to be Plain-Jane.  They can be dressed up with edge treatments such as a bevel or round-over.

Engraving and 3-D Engraving 

As is true of the FCO letters above, Engraving can be done on many materials.

With Flat-Engraving, the engraved area is left flat.

With 3-D engraving, a pointed bit is used which leaves a V-Cut or "Chisled" bottom.  This technique allows the bit to travel out of the cuts in such a way as to leave the corners nice and sharp.

Sometimes a combination of the two is needed as in the photo at the right.  If you look closely you'll see a flat bottom with beveled edges and sharp corners.

Inlays and Push-Throughs

With Inlays, a pocket is cut into the background material and another piece is cut to fit into the pocket like a jigsaw puzzle piece.  The inlaid piece may fit down flush with the back or extend up above it.  What with the many different combinations of materials, colors and techniques, the possibilities here are endless.

With Push-Throughs, letters are cut (usually acrylic) to fit through matching holes cut into a thin panel (usually aluminum).  The letters usually extend out beyond the surface of the back and are often lit from behind.

True Prismatic and Simulated Prismatic

True Prismatic letters are way cool.  But they are also a lot of work.  Simulated Prismatic letters are also pretty cool and a lot easier to make.

At right you see a Reverse Simulated Prismatic Letter.  These letters and graphics are usually made to be used in molds for concrete signs.  There is somewhat of an art to this as many parameters have to be considered to achieve the desired result.

Unusual Techniques

As they say, "Necessity is the mother of invention!"  Some of the challenges we've faced have resulted in our developing new techniques.  Pictured at right are two examples of our "Folded Aluminum" Technique.

Others include "Simulated Woodgrain", "Pebble Texture" on Engraved Signs,  Custom "Vandalized" Finishes, "Simulated Wrought Iron" Technique and others.