Technical advice for sign makers

Before approving a new configuration, we test the actual face material in a light box. This allows us to compare LEDs and determine:

• the most suitable LED model;
• the spacing between LED rows;
• the pitch, meaning the spacing between modules;
• the right balance between uniformity, intensity and module quantity.

If you do not yet have a light box, we can provide the files required to build one.

A sign containing more LEDs is not necessarily better illuminated. Above a certain intensity, the human eye perceives little or no additional light. Correct sizing therefore means finding the useful light level, rather than installing the maximum number of modules.

Over-equipping creates several unnecessary costs:

• more modules to purchase and install;
• higher electricity consumption;
• potentially larger or additional power supplies;
• more wiring, connections and heat to manage;
• wasted materials without sufficient visible improvement.

The light box and LED layout help identify the best balance between uniformity, intensity, reliability and production cost.

Sizing is calculated by multiplying the number of LEDs or modules by their power consumption in watts and using the operating range specified for each power supply.

The cable cross-section and system distribution must be suitable for the length and power being carried. An insufficient cross-section can cause overheating and create a fire risk.

The MEAN WELL power supplies selected by Domino Sign are designed for intensive professional use. Waterproof, reliable and durable, they provide a stable supply for all LED solutions, both indoors and outdoors (protected installation recommended).

Domino Sign helps customers select power supplies, distribute loads and apply the appropriate wiring precautions. The final installation must comply with the technical data sheets, applicable electrical regulations and actual installation conditions.

The same LED is not installed in the same way inside an indoor letter, an outdoor light box or a sign exposed to moisture. Module fixing, cable routing, connection protection and power-supply positioning must be adapted accordingly.

Outdoors, sealing must not prevent condensation management. Depending on the project, the design must include ventilation or water drainage while protecting components and connections.

The IP protection rating must be considered when deciding whether an LED product is suitable for outdoor use.

The Domino Sign calculator is designed to quickly estimate the complete cost of a sign. Using the dimensions, selected LED model and planned number of rows, it automatically calculates the required number of modules.

It also recommends suitable power supplies and produces a detailed estimate covering materials, Bender production time, assembly time and labour costs. Its purpose is to provide a clear view of production costs and make quotations easier to prepare.

Its limitation: the calculator costs a configuration, but it does not validate the lighting result. It therefore does not replace a light-box test, which is essential for confirming the LED model, pitch and number of rows according to the face material, its thickness and the geometry of the sign.

For a neon tube project, we prepare a precise quotation covering the lengths, power supplies, connectors, end caps and required accessories. An installation plan can be included to make preparation and fitting easier.

We also offer reinforced flexible neon selected for easy handling and installation. The profile, bending direction, length, colour and conditions of use must be confirmed according to the letter, logo or signage being produced.

All our products have a technical data sheet. It contains the key information required for selection and implementation: voltage, power, dimensions, module pitch where applicable, conditions of use and product limitations.

These documents complement our team’s advice. They provide the workshop with a reliable reference for preparation, installation and maintenance, but do not replace configuration approval when a project falls outside applications that have already been validated.

Domino Sign distributes a complete range of coils for channel letter production throughout Europe. Depending on the product, heights range from 20 to 200 mm, covering both small letters and high returns.

The range includes raw aluminium, pre-painted aluminium in different colours and stainless steel with several finishes, including brushed and mirror. We also offer profiles developed to simplify the assembly of faces and backs.

Selection is not based on colour alone: it depends on the machine used, the type of letter, return height, assembly method, environment and required finish.

The 1050 H24 alloy offers the right balance for sign production: it forms accurately, retains good rigidity and remains compatible with common assembly methods, including welding for the products intended for this purpose.

Material consistency is just as important as its designation. Domino Sign has maintained the same aluminium selection for years so that bending behaviour remains stable from one coil to the next.

This consistency helps workshops equipped with a Bender preserve their calibrations, accuracy and production repeatability over time.

The white interior reflects the light emitted by the LEDs inside the letter more effectively. It helps reduce light loss and distribute the luminous flux more evenly towards the diffusing face.

This finish helps achieve a more uniform result, regardless of the external colour of the letters.

The 1.2 mm raw aluminium provides the material and rigidity required for production methods that include welded assembly. The 1.1 mm pre-painted aluminium maintains the strength and quality expected from a professional letter while incorporating its finished surface.

Material that is too thin can deform more easily, show marks and produce a less regular return. Thickness therefore contributes directly to the perceived quality of the letter.

The accuracy of our Bender machines makes it possible to process these thicknesses without making manual finishing a systematic step.

316L combines a high-quality finish, good suitability for the intended manufacturing operations and enhanced corrosion resistance. It covers a wide range of indoor and outdoor applications.

It provides superior corrosion resistance through the addition of molybdenum (2 to 3%) and its low carbon content. It is ideal for marine environments, chlorinated areas such as swimming pools and aggressive industrial environments.

Main benefits:
- Marine resistance: withstands salt water and sea spray without rusting.
- Excellent weldability: the low carbon content (maximum 0.03%) helps prevent corrosion around welds.
- Chemical resistance: performs well against acids and powerful cleaning products.
- Long service life: provides excellent long-term durability for outdoor equipment.

Our profiles have been developed to make normally time-consuming assembly operations easier. Depending on the product, reinforcements create a more practical bonding area for the face, while a clip system secures the back.

EasyClip-type solutions reduce the number of visible fasteners, improve assembly consistency and can make the letter easier to open for maintenance.

There is no universal adhesive. The choice depends on the materials, the purpose of the bond, the size of the letter, expected movement and the environment.

Contact adhesive + activator: provides an almost immediate hold during assembly. This initial fixing must be reinforced with a suitable flexible adhesive.

TS40: a transparent, flexible and watertight bond for letters with aluminium returns and a PMMA face, in the applications covered by its technical data sheet.

White Rotabond 2000: high adhesion and excellent flexibility to better absorb movement, particularly on certain large letters.

Surface preparation, joint dimensions, support during curing and polymerisation time are just as important as the selected product. Technical data sheets and compatibility tests must be followed.

The choice first depends on materials, profiles, return heights, the operations to be automated and expected volume. Available space, the team’s level of experience and the future development of the business must also be considered.

• Easy Sign Bender SE: a compact, versatile solution for Domino Sign profiles and flat strips.
• Super Channel Bender SXP: more comprehensive automation for high volumes and flange or punching operations.
• Lite Channel Bender LX200: a machine designed for demanding materials and high returns.
• Channel Bender RT: a specialised solution for profiles and technical materials, including certain types of stainless steel.

Digital processing allows returns to be prepared from the same file as the faces and backs. The workshop can therefore organise cutting, bending and assembly more efficiently while reducing manual adjustments.

The benefit is not speed alone: it also means more consistent production, greater repeatability and increased capacity to handle orders.

The calculation must start from the workshop’s actual situation: monthly volume, current manual production time, fully loaded hourly cost, possible subcontracting, rework rate and potential new sales.

Working formula: monthly volume × time saved per letter × workshop hourly cost × 12.

For example, an estimated saving of 10 minutes across 150 letters represents 25 workshop hours freed up each month. The financial value of these hours then depends on the company’s actual costs.

These figures provide an order of magnitude only and are never a guaranteed level of performance. Domino Sign prepares a personalised simulation before presenting an estimated return on investment.

No. The value created depends on the starting point:

• Manual production: time saved, lower labour costs and greater consistency.
• Already-equipped workshop: reliability, production comfort, support and fewer reworks.
• Subcontracted letters: recovered margin, independence and control of lead times.
• New activity: the opportunity to offer dimensional letters and develop additional revenue.

A serious assessment also considers avoided rework, consistency, reduced dependence on a highly experienced operator, shorter lead times and the ability to accept more orders.

Profitability is therefore measured in time freed up, recovered margin, additional capacity and new sales made possible.

Our role begins before the order and continues after installation: needs analysis, demonstration, tests using the customer’s files, delivery, installation and Qualiopi-certified professional training.

We then provide support with file preparation using SDSBenderCAD, initial projects, production optimisation, technical support and long-term after-sales service.

The workshop can also receive advice on materials, profiles, LEDs and assembly methods. This overall approach improves the complete production process, not only bending.

Channel3D is particularly suited to indoor applications involving small illuminated letters, logos, detailed or complex shapes and small batches that would normally require extensive handling.

Additive manufacturing creates the return and certain details directly from the file, before an illuminated face is produced with AcrylicSign resin. It can therefore reduce cutting, forming and bonding operations in suitable applications. This makes the technology highly accessible, whatever the operator’s previous experience in the sign industry.

Not at all. Production can start from a 2D vector file, which is converted into a usable production shape by the software supplied with the machine.

In the software, the operator sets the required parameters: height, depth, wall thickness, back shape, cable passages, positioning features and fixing requirements.

The quality of the original file and the parameter choices remain essential. Domino Sign trains the team in all these stages when the printer is installed.

The workflow is organised around three complementary stages:

1. Prepare the file: check the vector artwork and define the dimensions, walls, back and technical features.
2. Print the structure: produce the return and shapes using the Print800 and suitable filament.
3. Create the face: apply AcrylicSign acrylic resin and then cure it in the UV800 machine.

This organisation reduces certain manual operations and improves control over repeatability. Precise production settings are defined during training and adapted to the materials, dimensions and required finish.

The Print800 was developed to manufacture sign components. Its large build platform can produce several parts or larger formats, while automatic levelling makes job preparation easier.

Its stable architecture is designed to provide consistent extrusion. The 2-in-1 nozzle can process two colours or two material functions within the same job, depending on the selected configuration.

Using reinforced 2.85 mm filament provides a flow rate and rigidity suited to letter structures. Actual capabilities nevertheless depend on geometry, settings, material and the required finish.

Channel3D 2.85 mm filaments are selected for stable extrusion, rigid walls and good resistance to handling. Depending on the project, opaque, transparent or diffusing versions can be used to adjust the appearance of the structure.

AcrylicSign is a UV-curable acrylic resin developed for creating faces. It produces a smooth, uniform surface and light diffusion suited to the configuration being studied.

Colours, resin thickness, curing time and the LED all affect the final result. These parameters are validated together so that the face, structure and lighting operate as one coherent system.

Digital design makes it possible to include bonding surfaces, cable passages, positioning features and, depending on the project, clips or fixing recesses.

These details must be planned before printing. They affect assembly time, access to the LEDs, ventilation and ease of installation on the final support.

The weight of the letter, the type of wall or panel, access to the power supply and maintenance requirements must still be checked for each installation.

Channel3D can simplify the preparation of certain letters, reduce labour requirements, continue producing unattended, improve batch consistency and make shapes accessible that are difficult to produce using traditional methods.

The solution can also help the workshop respond more quickly and develop new ranges of illuminated letters, logos and customised signage.

Actual gains vary according to dimensions, quantities, finish, assembly time and the current organisation. Domino Sign therefore reviews the customer’s typical projects before presenting the expected benefits.

We do not simply deliver the machines. Support can begin with a needs assessment, demonstration and tests using the customer’s own files to confirm that the solution matches their production requirements.

After installation, we provide training directly in the customer’s workshop.

Technical support and after-sales service then help the workshop over time and enable it to optimise production as its experience and applications develop.

Depth is an important criterion, but it is not enough. The minimum and maximum stroke widths, the face material and its light transmission, the colour, any applied vinyl and the expected light level must also be known. We use this information to select the type of LED, its spacing and the number of rows, then check the configuration against a real case or comparable test.

The beam angle, spacing between LEDs, distance between rows and available depth must all be adapted. Corners, narrow returns, reinforcements and cables can also create shadows. Testing in a light box with the actual face material remains the safest method for a new or highly constrained configuration.

Selection mainly depends on the materials and profiles used, their heights and thicknesses, the type of letters to be produced, production volume and the operations you want to automate. File preparation, available space, training, maintenance and return on investment must also be considered. Domino Sign examines these points before recommending a model.

Traditional manufacturing remains suitable for many formats and finishes. 3D printing is particularly useful for small letters, complex shapes, customisation and reducing certain assembly stages on indoor projects.

Where possible, send a vector file at the correct scale, the planned materials, face type, required lighting result, installation conditions and several photographs. For an LED project, also indicate the position of the power supplies. The more complete the context, the more precise our response can be.