Dimensional letters are 3D, individual letters commonly used for mounting to internal and external building walls. These letters are made from various materials, including metals, plastics, and wood. The most common method for making dimensional letters is cutting them from a sheet of material. Choosing a Substrate The first step in making dimensional letters is to select a substrate, or material, the letters are cut from. Aluminum Aluminum is made by taking bauxite ore and smelting it in an aluminum refinery. This process removes impurities from the ore and leaves a pure aluminum alloy behind. This alloy is then cast into ingots, large blocks of aluminum, which are easy to work with. Next, the ingots are pressed into sheets. These sheets are then cut to be made into dimensional letters. PVC PVC, or polyvinyl chloride, is another popular substrate for dimensional letters. PVC is made by combining vinyl chloride with ethylene to create a plastic. This plastic is molded into sheets, which are then cut to manageable sizes and sent to a sign shop. Wood Wood is a traditional substrate for dimensional letters. The most common type of wood used for dimensional letters is plywood. Plywood is made by taking thin sheets of wood and gluing them together. This process creates a stronger piece of wood that is less likely to warp or crack. Cutting the Letters Dimensional letters are shaped in several ways, including hand-carving, CNC routing, and laser cutting. Hand-Carved Letters Hand-carving letters is the oldest and most traditional method for creating dimensional letters. This method is still used today but is much less common than it once was. Carving letters by hand requires a great deal of skill and experience. First, the letter carver must design a template of the letter they wish to carve. This template is then used to guide the carving of the letter from the substrate. Hand-carved letters are typically made from wood. CNC Routed Letters CNC (computer numerical control) routing is a modern method for creating dimensional letters. This method uses a computer-controlled router to carve the letters into the substrate. CNC routing is a fast and accurate way to make dimensional letters. It is also very versatile, as it is used to create letters of any size or shape. Laser Cut Letters Laser cutting is a precise and clean way to create dimensional letters. A laser cuts the letters from the substrate. Laser cutting is popular for dimensional letters because it is precise and makes very intricate designs. It is also fast and clean, with little or no cleanup required. At FASTSIGNS® of Sacramento - Arden-Arcade, CA, we make custom dimensional letters for all types of businesses. Contact us today to learn more.