Metal Letters Led Sign – Aglare® LED Letters

How to Make LED Channel Letters: Step-by-Step Manufacturing Process

aglareadmin — Wed, 19 Aug 2026 05:41:49 +0000

LED channel letters are among the most technically demanding products in the sign-making industry. The combination of metal fabrication, precision cutting, acrylic forming, and LED electrical assembly requires a range of skills and equipment not found in every sign shop. This guide walks through the complete manufacturing process — useful both for sign makers assessing their own capability and for buyers wanting to understand what they are paying for.

Essential:
CNC router: For acrylic face cutting and aluminum back pan cutting
CNC bending brake (or manual brake for smaller shops): For forming aluminum return channels
TIG or MIG welder: For joining stainless steel letter forms
Letter bender (return bending machine): Dedicated tool for bending 50-100mm aluminum channel into letter shapes
LED strip cutter: Precision cutting of LED strip at correct intervals
Riveting tools and pop rivets: For joining aluminum components
Spray paint booth (or powder coating arrangements with a sub-contractor)
Recommended:
CO₂ laser cutter: Far more precise and faster than CNC router for acrylic and thin aluminum
Vinyl cutter: For face vinyl graphics and color-change films
LED test bench: To pre-test LED strip sections before assembly

Material Specifications

Letter Returns (Sides)
Aluminum return (most common):
Material: 1.0–1.5mm aluminum sheet
Finish: Powder-coated in any RAL color
Stainless steel return (premium):
Material: 1.0–1.2mm 304 stainless steel
Finish: Brushed (2B or hairline) or mirror polished
Used for halo-lit and premium front-lit letters
Letter Back Pan
Material: 1.0–1.5mm aluminum sheet
Typically painted white (interior) for maximum light reflectivity
Pre-drilled for mounting and cable entry
Letter Face
Material: 3mm–5mm acrylic sheet
Translucent grades for front-lit; solid color or opaque for halo-lit
Thickness: 3mm for letters up to 600mm tall; 5mm for larger
LED Strip
COB strip (preferred for uniform face illumination): 24V, 480–720 chips/m, IP65
SMD 2835 strip (budget alternative): 24V, 120 LEDs/m, IP65
Both must be self-adhesive backed for installation inside the letter

Step 1: Artwork Preparation and Font Layout

The sign file must be converted to a vector format suitable for CNC cutting. Key considerations:
Minimum letter stem width: 60mm for 100mm depth; wider for deeper letters (structural rigidity)
Minimum internal radius on curves: matched to the letter bender’s minimum radius capability
Font stroke width must accommodate the LED strip and internal wiring

Step 2: CNC/Laser Cutting of Face

The acrylic face is cut on the CNC router or laser to the exact letter outline. Laser cutting produces smoother edges and requires less post-processing. The face is typically cut slightly larger than the return footprint so it overlaps the return edge by 3-5mm for a clean aesthetic.

Step 3: Return Bending

The aluminum or stainless steel return is formed into the shape of the letter perimeter using the letter bending machine. This step requires skill — the return must follow the letter contour precisely, with consistent depth throughout. Stainless steel returns are more difficult to bend cleanly and require more experienced operators.

For complex letter shapes (tight curves, diagonal strokes), the return may need to be fabricated in multiple sections joined by welding or riveting.

Step 4: Back Pan Cutting and Preparation

The back pan is cut (CNC or laser) to the letter outline. Holes are drilled for:

Power cable entry
Mounting stud positions
Drainage holes (to prevent water accumulation in outdoor installations)
The interior of the back pan is painted flat white to maximize LED light reflection.

Step 5: LED Strip Installation

The LED strip is cut to the required lengths and installed inside the letter on the back pan (for front-lit) or on the return (for halo-lit).

Critical for uniform face illumination:

Strip-to-face distance: 30–60mm (depending on letter depth and strip output)
Strip routing: Follow the letter perimeter shape; a single U-shaped strip in the bottom of the letter is NOT adequate for uniform illumination
Strip density: For a 100mm deep letter with COB strip, one run of COB strip on the back pan typically provides adequate uniformity

Step 6: Driver Selection and Mounting

Calculate the total LED strip wattage in the letter. Select a LED driver rated at 125% of this load. For outdoor installation, the driver must be IP67-rated and mounted in a weatherproof location accessible for maintenance.

For large signs with many letters, consider centralized drivers in a weatherproof enclosure rather than per-letter drivers.

Step 7: Wiring and Assembly

Connect the LED strip sections within the letter using clip connectors or soldered connections. Bring the power feed cable out through the back pan cable entry hole. Test the LED operation before assembly is completed.

Rivet or spot-weld the return to the back pan around the perimeter. Secure the face to the return using acrylic adhesive or mechanical retaining clips (clips allow face removal for future service access).

Step 8: Final Testing and Quality Check

Before delivery:Power on and verify uniform face illumination (no dark spots, hot spots, or color variation)
Check all edges for clean lines — no return kinking, no face edge chips
Verify waterproof sealing of the cable entry and back pan joints (for outdoor letters)
Check mounting stud positions match the installation drawing

3D Light up Letter Lights Metal LED Marquee Letters

aglareadmin — Fri, 07 Jun 2024 09:05:31 +0000

Product Description

Custom 3D Light up Letter Lights Metal LED Marquee Letters,3D LED Channel Letters & Signs

We can supply all event letters and numbers.

The 3D light up letters and numbers range includes A to Z, 0 to 9, symbols such as ! (exclamation mark), @ (at sign), # (hashtag), & (ampersand), ? (question mark), ☆ (star), ♡ (heart).

Choose any other shape

We can turn anything into giant light up signs up to 4-5 feet tall. A perfect way to impress your guests at retail stores, trade shows, amusement theme park,theme park lighting.brand activation events, restaurants. Everyone will want to take photos with it and share them on their social media. See our custom marquee shapes here.

*Please reach out to find out shipping costs, the shipping price listed is not accurate, because all orders are custom, so they will have different heights and weight*

FAQs

Q: How do I place a custom order?
A: Please contact us with your specific requirements and we will help you place your order.

Q: Are the lights in the letters replaceable?
A: Yes, the lights in our metal letters are replaceable, offering flexibility and longevity.

Q: Is shipping included in the price?
A: No, the shipping cost is separate as each order is custom and will have different weights and sizes. Please reach out to determine accurate shipping costs.

Q: Can these be used outdoors?
A: Yes, these letters are designed for both indoor and outdoor use, making them a versatile choice for any event or occasion.

Indulge in our Metal Letters with Lights Illumination Letter Signs and create a memorable, captivating atmosphere for your next event.

Product Details

Choose any 3D light up letter & LED metal letters signs

We can make 3D light up letter marquee letters A-Z, marquee numbers 0-9, and marquee symbols. Pricing provided is based on our default font, but we can do any fonts at an additional cost.

Choose any color

Letters can be made in any color, at an additional cost. Get creative and choose a different color for each letter if you’d like! See our colorful marquee letters here.

Choose any display option

(a) Freestanding letters

Freestanding letters can balance on their own on flat ground. We include wedges for letters that have a rounded bottom like the letter O. But it is your responsibility to decide when a stand is needed for safety. If you are setting up outdoor, in a windy area, or not setting up a perimeter around the letters to avoid people from bumping into it (including but not limited to these circumstances), then a stand is required for safety. We offer stands at an additional cost.

(b) Wall-hanging letters

Wall-hanging letters will have hooks attached on the back side of the letters. Additional charges may apply, such as hanging larger letters, or adding a backplate.

Marquee Led Sign Mr&Mrs 3D Metal Marquee Letter Light Up Marquee Sign

aglareadmin — Fri, 07 Jun 2024 08:56:04 +0000

Product Description

Custom 3D Metal Marquee Letter Light Up Marquee Sign,3D LED Channel Letters & Signs

3D light up letters and numbers range from A to Z, 0 to 9, symbols such as !(exclamation mark), @(at sign), #(pound sign), &(ampersand), ?(question mark), ☆(asterisk), ♡(heart).

Our metal 3D light up letters are not only beautiful but also very versatile. They can be used in a variety of ways to enhance your event decor. The perfect way to impress your guests at retail stores, trade shows, amusement parks, theme park lighting, brand activation events, restaurants. Whether you want to spell out a special message, highlight the initials of a happy couple, or create a charming backdrop, these letters can do the job.

*Please contact us for shipping costs, the shipping costs listed are not exact as all orders are custom made so they will vary in height and weight*

Product Details

Choose any 3D light up letter & LED metal letters signs

We can make 3D light up letter marquee letters A-Z, marquee numbers 0-9, and marquee symbols. Pricing provided is based on our default font, but we can do any fonts at an additional cost.

Choose any color

Letters can be made in any color, at an additional cost. Get creative and choose a different color for each letter if you’d like! See our colorful marquee letters here.

Various sizesChoose from Metal Led Letter Signs and LED Illuminated Sign Letters in different sizes from small to extra large.
Bright colorsCustomize your Led Letters Sign & metal luminous characters sign with your favorite color.
Various stylesChoose your favorite style, your preferred backplate, hanging options for your controller, and many other options.

Custom Light Up Letter Sign,ABC Marquee Letters with Lights

aglareadmin — Fri, 07 Jun 2024 08:43:01 +0000

Product Description

Custom Light Up Letter Sign,Metal Marquee Letters Light,Marquee Letters with Lights

Choose any LED metal letters signs,We can supply all event letters and numbers.

The light up letters and numbers range includes A to Z, 0 to 9, symbols such as ! (exclamation mark), @ (at sign), # (hashtag), & (ampersand), ? (question mark), ☆ (star), ♡ (heart).

Choose any color

Letters can be made in any color, at an additional cost. Get creative and choose a different color for each letter if you’d like! See our colorful marquee letters here.

Choose any other shape

Product Details

Our LED Letters Sign offers you a choice from a spectrum of vibrant colors to perfectly match your event theme and setting. You can also select from multiple styles to give your occasion that unique touch of personality.

Various sizesChoose from Metal Led Letter Signs and LED Illuminated Sign Letters in different sizes from small to extra large.
Bright colorsCustomize your Led Letters Sign & metal luminous characters sign with your favorite color.
Various stylesChoose your favorite style, your preferred backplate, hanging options for your controller, and many other options.

Marquee Letters Large Metal Letters Sign Logo

aglareadmin — Fri, 07 Jun 2024 07:55:57 +0000

Product Description

Custom Metal Stainless Steel Advertising LED Letter Lights Sign Logo,Metal Light Up Letter

Metal Light up letters are stunning soft, glowing lights that will make your space so much more romantic. These giant LED metal letters marquee letters will be a gorgeous photo op and enhance the warm atmosphere. The options are endless when it comes to taking your event lighting to the next level.

【DIY Combination】AZ letters, 0-9 Arabic numbers and symbols &, free to form words or add themes for different festivals and anniversaries, advertising signs. For example, any combination into I LOVE U, HOME, MARRY ME, HAPPY, etc., you can also choose the initials of your name symbols, such as J&M, to use your imagination.

【Widely Used】Use our large metal letters with lights, perfect for illuminating any project, signs, wedding or birthday letters, outdoor, bars, cafes, playground sign decorations, etc., they are long-lasting and durable. These LED letter lights and sign letters can be used to create spectacular backgrounds, decorate ceilings and walls, and illuminate the outdoors, adding infinite charm to the atmosphere

*Please reach out to find out shipping costs, the shipping price listed is not accurate, because all orders are custom, so they will have different heights and weight*

Product Details

【Light Up Letters】: Made of high-quality 304 stainless steel + LED, durable and reusable. Each one emits a gorgeous warm white light, very cute and stylish. This marquee light is the perfect size for easy carrying, perfect for indoor outdoor commercial sign lighting / amusement theme park / night light wedding / birthday party Christmas light home bar decoration.

Various sizesChoose from Metal Led Letter Signs and LED Illuminated Sign Letters in different sizes from small to extra large.
Bright colorsCustomize your Led Letters Sign & metal luminous characters sign with your favorite color.
Various stylesChoose your favorite style, your preferred backplate, hanging options for your controller, and many other options.

Metal Letter Signs With Lights 60cm

aglareadmin — Fri, 07 Jun 2024 07:41:36 +0000

Product Description

Custom Metal Letter Signs With Lights,Star Marquee Light,Light Up Letter

【Star Marquee Lights】Made of high-quality 304 stainless steel + LED, the stainless steel material can be used outdoors for more than 5 years. They have a 270-degree wide angle, super bright light source, and can be customized with animation effects. These star marquee lights can be used for commercial advertising, amusement park signage, and decoration of outdoor entertainment equipment.

*Please reach out to find out shipping costs, the shipping price listed is not accurate, because all orders are custom, so they will have different heights and weight*

Product Details

We can supply all event letters and numbers.

The light up letters and numbers range includes A to Z, 0 to 9, symbols such as ! (exclamation mark), @ (at sign), # (hashtag), & (ampersand), ? (question mark), ☆ (star), ♡ (heart).

Various sizesChoose from Metal Led Letter Signs and LED Illuminated Sign Letters in different sizes from small to extra large.
Bright colorsCustomize your Led Letters Sign & metal luminous characters sign with your favorite color.
Various stylesChoose your favorite style, your preferred backplate, hanging options for your controller, and many other options.

Star Marquee Light, Metal Letters With Lights

aglareadmin — Fri, 07 Jun 2024 07:35:42 +0000

Product Description

Illuminate your business or personal space with our high-quality Custom Stainless Steel Light-Up Letter Signs complete with Star Marquee Lights. These are not your usual signage – these are uniquely constructed from durable 304 stainless steel, ensuring longevity of use for more than 5 years even when used outdoors.

Our star marquee lights possess a unique full-view lighting feature with a 270-degree wide-angle capacity. The super bright LED lights maintain excellent visibility and impact, ensuring your signs stand out day or night. And, to make things more fun, these lights are customizable to exhibit animation effects, adding more charm to your signs!

Perfect for using in a variety of settings – be it commercial advertising, amusement park signage, or outdoor entertainment equipment decoration. Each order is custom-made, designed to cater to your specific requirements. Allow us to personalize your light-up letter signs and make your name or business shine with style and sophistication.

Please note: Since every order is customized, the shipping cost will vary depending on the dimensions and weight of the package. Please get in touch with us to get accurate shipping costs for your order.

Product Details

Customizable LED Illuminated Letters & Numbers for Events，Take your events to the next level with our extensive range of versatile LED Illuminated Sign Letters. We offer a full array of English alphabetical letters from A-Z, numbers 0-9, and a plethora of popular symbols including a heart, star, question mark, exclamation mark, at sign, hashtag, and ampersand.

For those seeking a more classic approach, our Metal LED Letter Signs are sure to impress. Each metal character is meticulously crafted and fitted with efficient LED lights to ensure you receive high-quality luminous sign letters.

Both our Metal and LED options come in a range of sizes from small to extra-large, making them perfect for any occasion or space. Plus, with customizable backplates and hanging options, you can personalize every detail to meet your event’s needs.

Take advantage of our versatile and customizable illuminated sign letters to make your event truly unforgettable. Whether you’re hosting a grand occasion or a cozy get-together, our magnitude of options will help you create the perfect ambiance, making your celebrations memorable. We’re here to offer all the light up letters and numbers you could need.

C Metal Letters with Lights Illumination Letter Signs

aglareadmin — Fri, 07 Jun 2024 07:31:26 +0000

Product Description

Custom Metal Letters with Lights Illumination Letter Signs,Marquee Letters Light

Our product line includes LED Metal Letters Signs that cover all alphabets from A-Z along with numbers from 0-9. As they are custom-made, the size and weight will vary based on your order. Please contact us to discuss your specific needs.

How the Product Works

These Metal Light Up Letters are effortless to operate. Once they are set up in your chosen layout, simply plug them in and watch as they cast a warm, inviting glow, instantly enhancing the ambiance of your space. They are also ideal for creating eye-catching displays, memorable photo-ops, and for adding a special touch to your event.

*Please reach out to find out shipping costs, the shipping price listed is not accurate, because all orders are custom, so they will have different heights and weight*

FAQs

Q: How do I place a custom order?
A: Please contact us with your specific requirements and we will help you place your order.

Q: Are the lights in the letters replaceable?
A: Yes, the lights in our metal letters are replaceable, offering flexibility and longevity.

Q: Is shipping included in the price?
A: No, the shipping cost is separate as each order is custom and will have different weights and sizes. Please reach out to determine accurate shipping costs.

Q: Can these be used outdoors?
A: Yes, these letters are designed for both indoor and outdoor use, making them a versatile choice for any event or occasion.

Indulge in our Metal Letters with Lights Illumination Letter Signs and create a memorable, captivating atmosphere for your next event.

Product Details

Metal Led Letter Signs,Metallic luminous letters, marquee letter lights, LED luminous letters suitable for outdoor sign advertising, amusement park theme park, wedding, birthday party Christmas lights home bar decoration

Durable material

The letters are made of 304 stainless steel, 1.0 thick, with fully enclosed frames on both sides for added strength. They are strong and durable, and can be safely transported and installed at events.

Various sizesChoose from Metal Led Letter Signs and LED Illuminated Sign Letters in different sizes from small to extra large.
Bright colorsCustomize your Led Letters Sign & metal luminous characters sign with your favorite color.
Various stylesChoose your favorite style, your preferred backplate, hanging options for your controller, and many other options.

Custom Large 2ft3ft4ft Tall LED Metal Letters with Lights

aglareadmin — Fri, 07 Jun 2024 07:26:25 +0000

Product Description

Custom Metal LED Letters A with Lights, 2ft3ft4ft ,Marquee Letters Light ,LED Illuminated Sign Letters,Light Up Letter

Illuminate your special moments with our Metal Light up Letters. These captivating LED metal letters feature soft, glowing lights that imbue a romantic flair into any space instantly. These LED letter lights and sign letters can be used to create spectacular backdrops, decorate ceilings and walls, and light up the outdoors, adding infinite charm to the ambiance.

Our collection includes a diverse range of LED metal letters, signifying all 26 alphabets and 10 numbers, enabling you to personalize your messages for any occasion. You could choose the popular ‘MR & MRS,’ a giant heart symbol, a marquee ring, or event the wedding couple’s last name to make your event more memorable.

But our marquee letters are not limited to indoor use, they have proved to be a popular choice for Outdoor Sign Lighting, Amusement Theme Parks, Night Light Weddings, Birthday Parties, Christmas Lamp Home Bar Decorations. They are designed for durability, ensuring long-lasting use while maintaining their aesthetic beauty.

Each of these LED letter lights is crafted to be a decorative masterpiece, transforming ordinary backdrops into spectacular visual canvases, embellishing walls and ceilings with enticing patterns of light, and infusing the outdoor settings with an irresistible charm.

Invest in our Metal Light up Letters and bring a dramatic effect to your event lighting or home decoration needs, adding a unique touch of sophistication and grandeur to any space or occasion.

*Please reach out to find out shipping costs, the shipping price listed is not accurate, because all orders are custom, so they will have different heights and weight*

Product Details

Choose any LED metal letters signs

We can make marquee letters A-Z, marquee numbers 0-9, and marquee symbols. Pricing provided is based on our default font, but we can do any fonts at an additional cost.

Various sizesChoose from Metal Led Letter Signs and LED Illuminated Sign Letters in different sizes from small to extra large.
bright colorsCustomize your Led Letters Sign & metal luminous characters sign with your favorite color.
Various stylesChoose your favorite style, your preferred backplate, hanging options for your controller, and many other options.

Large 2ft3ft4ft Tall Metal LED Light Letters V

aglareadmin — Fri, 07 Jun 2024 07:22:54 +0000

Product Description

Custom Light Up Letter,Large 2ft3ft4ft Tall Metal LED Light Letters,Marquee Letters Light

【Light Up Letters】Made of high-quality 304 stainless steel + LED, durable and reusable. Each one emits a gorgeous warm white light, very cute and stylish. This marquee light is the perfect size for easy carrying, perfect for indoor outdoor commercial sign lighting / amusement theme park / night light wedding / birthday party Christmas light home bar decoration.

【DIY Combination】AZ letters, 0-9 Arabic numbers and symbols &, free to form words or add themes for different festivals and anniversaries, advertising signs. For example, any combination into I LOVE U, HOME, MARRY ME, HAPPY, etc., you can also choose the initials of your name symbols, such as J&M, to use your imagination.

【Widely Used】Use our large metal letters with lights, perfect for illuminating any project, signs, wedding or birthday letters, outdoor, bars, cafes, playground sign decorations, etc., they are long-lasting and durable. These LED letter lights and sign letters can be used to create spectacular backgrounds, decorate ceilings and walls, and illuminate the outdoors, adding infinite charm to the atmosphere.

*Please reach out to find out shipping costs, the shipping price listed is not accurate, because all orders are custom, so they will have different heights and weight*

Product Details

Transform the ambiance of any space with our Metal Letters with Lights Illumination Letter Signs, guaranteed to make your special occasion extraordinary with their warm glow and eye-catching design.

Product Features

Choose any LED metal letters signs

We can make marquee letters A-Z, marquee numbers 0-9, and marquee symbols. Pricing provided is based on our default font, but we can do any fonts at an additional cost.

Choose any other shape