Halo Lit Custom Channel Letter Sign

Our friends at Crestron Electronics hired us to create a front desk lobby sign for their headquarters.  We’ll be creating custom channel letters with high gloss black finish mounted to a satin metal box and lit with LEDs.  The challenge with this sign was that the box was about 110″ long and our cutting bed was only 96″. So with some creative maneuvering we were able to make the cuts.

Here we are cutting the letters for our sign out 1.5″ 30lb Precision Board.  These will be real heavy duty letters and the 30lb density foam will allow us to get a nice smooth finish. You can see the drill holes for the screw posts which we will use to mount the letters once complete.  We have also hogged out a channel to allow for our LEDs.

cnclettersHere is cut one for the back side of our box. As you can see we cut only the first part – we then had to move the sheet of dibond and reregister it to the MultiCam table to allow for the second cut.cuttingbox2

Complete! and ready to mount the letters.


Brian has all the letters back from the paint shop and ready to go.


It’s time to install the LEDs, wire each letter and logo element then and then wire up the box.

wiring 2

Here Mark is measuring the LED output and calculating the final letter height.

markThe letters are going on nice and smooth but there is still a lot of wiring to go.


All done and ready to be installed.


Stone Wall Plaque

So our friend and client Julian came in last week with an interesting project. He was looking for a creative way to present a plaque to a colleague as a gift using their logo as the artwork. So we came up with the idea of doing a carved “stone” look.

We started by taking their logo and vectorizing it in Enroute Pro.

Once we had it as a vector file we are able to manipulate it and convert it to 3D then add stone texture.

Carved - Proof

Once we had the 3D all set it was time to cut it. It’s off to the MultiCam 3000!  We’re going to cut it from 1.5″ 30lb Precision Board so that finishing will be fast and easy. Here you can see what the first rough pass looks like along with the finish pass starting.


Now we’ll have a little fun and add some more stone texture with my favorite texture tool – a spackle knife.


We are ready to prime using Coastal Enterprises FSC-88 Primer/Filler.


Then we’ll paint the whole sign black. Here Mark is putting down two quick coats of Modern Masters Black Pearl.


Now to add the white detail of the logo. I’m going to add paint right into the carving then paint the face of the letters.



And here she is…


We’ll add a cleat to the back and it’s ready to hang.

Building Sign – The Athlete Recovery Center – Part 3: Painting

Well my job is done for awhile. I’ve designed and cut the sign. Now it’s Brians turn to work some magic in the paint shop. He’ll prep, prime and paint then assemble.

prime2 paint-black oval

Now it’s time for a little detail and adding the color.

closeup paint closeup paint 2

Great job Brian – Here are the signs ready to install. Stay tuned for the final install shots…

– Steve

Painted - all

Building Sign – The Athlete Recovery Center – Part 2: Cutting The Sign

So we did some more tweaking of the fonts to get it just right and tested the final design by placing a print on the front of the building. Dan, the client, was happy so it’s on to the 3D portion of the project.

Here we’ve added depth and texture to the design to give it a natural wood feel.

3D Design

Now we are ready to cut. I’m cutting these out of 15lb Precision Board HDU on our MultiCam 3000. We’ll then mount the signs to 3mm Dibond for extra rigidity.



3up Closeup

Now we are ready for assembly and paint!