In the world of advertising, LED epoxy resin letters are taking the spotlight. These letters, with their beautiful luminosity and durable build, have become the go-to choice for businesses worldwide. But how do you make them? Well, let’s walk you through the process step by step, using a channel letter machine. Don’t worry if you’re new to this—by the end of this guide, you’ll know exactly how to create your own epoxy resin letters.
Tools You’ll Need to Get Started
Before jumping in, let’s gather the necessary tools and machines. Here’s what you’ll need:
- Electric soldering iron
- Trimming or polishing machine
- Hot glue gun
- Channel letter bending machine
- Laser welding machine
- Co2 mixed laser cutting machine (for both acrylic inner support and metal backing) With these in hand, we’re ready to dive into the exciting world of epoxy resin letter crafting.
Step 1: Making the Channel Letter
The first step is to create the channel letter according to the desired font size. Most commonly, iron or stainless steel is used for channel letters. Occasionally, custom plastic letters are also chosen, especially for larger volumes. But generally, the typical letter depth ranges from 3cm (1.18 inches) to 10cm (3.93 inches).
How do we create the channel letter?
1. Cut the base plates: The Co2 mixed laser cutting machine is your best friend here. Use it to cut out the metal base and acrylic support plates.
2. Bend the sidewalls: Next up, use the channel bender machine to efficiently bend the corresponding sidewalls of the letter.
3. Weld the pieces together: Lastly, a laser welder helps to attach the sidewalls to the metal bottom plate, completing the 3D structure of the channel letter. Pretty cool, right? Now, let’s move on to the next step.
Step 2: Polishing the Channel Letter
Now that the structure is ready, it’s time to polish it up! After cutting and assembling the letters, we use 600 to 1200 mesh water sandpaper to roughen the edges and surfaces. This step ensures that any imperfections are smoothed out, giving the letters a clean finish.
It’s important to grind the letter repeatedly until it’s completely smooth. Think of this step as giving your letters a nice, polished shine!
Step 3: Adding a Splash of Color: Spray Painting
With the letters polished, the next step is to spray-paint the surface. Why is this important? The color and finish are often what catches a customer’s eye first. Depending on your client’s preferences, you can choose from various paint options.
Pro Tip: Use Fluorocarbon Paint
We recommend fluorocarbon paint for an even, durable finish. For the inside of the channel letters, using a special white reflective paint can help mirror and enhance the light emitted by the LEDs.
Step 4: Installing the LED Module
LEDs are what make epoxy resin letters stand out (literally). Installing the LED module is a crucial step. Here’s how you do it:
1. Clean the surface: Make sure the surface is free of any dust or debris.
2. Install the LED patch lamp: Carefully position the LEDs inside the letter.
3. Organize the wiring: Tidy up the wires, ensuring they’re evenly connected for a seamless look. Once everything is in place, it’s time to move on to the resin part!.
Step 5: Attaching the Acrylic Support Block
The acrylic support block is what gives the letter its sturdy backbone. To attach it:
1. Position the acrylic plates: Ensure the plates are correctly aligned within the channel letter.
2. Seal with a glue gun: Use the glue gun to firmly attach the acrylic panels, preventing any resin from leaking during the next step.
Step 6: Pouring the Epoxy Resin
Now, this is where the magic happens! Pouring the epoxy resin gives the letters their signature look. Here’s what you’ll need:
- Epoxy resin glue
- Light-diffusing agent
- Epoxy resin color paste – Reliable electronic scale
Mixing the Epoxy Resin
To get that perfect mix, follow this ratio:
- 3 parts glue A (soft and hard glue) + 1 part glue B
- Add 2% of the total weight of a light-diffusing agent to enhance brightness.
- Add 1% color paste for a splash of color. For example, if you’re using 300 grams of glue A, you’ll need 100 grams of glue B and mix it with the light-diffusing agent and color paste. Make sure to use an electronic scale to maintain consistency. Any miscalculation can affect the overall look of your letters.
Key Points to Keep in Mind
- Control the thickness of both the light guide layer and the uniform light layer.
- The resin should be poured with a 5mm gap from the top, especially when working with letters that are around 3cm thick.
- Don’t forget to cast a colorless, transparent layer for the light guide layer before moving on to the second layer.
Casting the Uniform Light Layer
The second layer of resin is called the uniform light layer. To mix this, combine:
- 3 parts glue A
- 1 part glue B
- 2-3% leveling agent
- 0.5 to 1% color paste Be sure to use the mixture within 35 minutes of mixing—after that, it will begin to thicken and won’t be as easy to work with.
Final Thoughts on Epoxy Resin Letter Making
There you have it! Crafting epoxy resin letters may seem complex at first, but with the right tools and a little patience, anyone can do it. From bending the metal to mixing the perfect resin, each step is important to creating those luminous, eye-catching letters that businesses love.
Summary
In this guide, we’ve walked through the detailed process of creating epoxy resin letters using a channel letter machine. From cutting and bending the materials to installing LEDs and pouring resin, each step builds on the last to create stunning, professional-quality signage. The beauty of this craft is that once you’ve mastered the basics, the possibilities are endless. You can experiment with different colors, sizes, and effects to create truly unique pieces.
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FAQs
1. What is the ideal thickness for epoxy resin letters?
The most common thickness for epoxy resin letters ranges from 3cm to 10cm.
2. Can I use plastic letters instead of metal for my channel letters?
Yes, some businesses opt for custom plastic letters in larger volumes, though metal is more common.
3. What type of paint should I use for the channel letter’s surface?
We recommend using fluorocarbon paint for a long-lasting, professional finish.
4. How long do I have to use the resin mixture before it thickens?
You have around 35 minutes to work with the resin before it starts to thicken.
5. Can I reuse thickened resin?
You can, but it’s best to use the resin when it’s still fresh. Once it thickens, the quality may not be as consistent.
