Improvements in CNC routing technologies over the past few years continue to open up profitable opportunities for savvy sign makers. New cutting tools and expanded software capabilities are now tailored specifically to cutting and trimming printed graphic signs on rigid as well as more flexible substrates and machining and carving three-dimensional signs and letters.

These new options also allow sign shops to their routers on softer substrates such as foam boards as well as denser substrates like acrylic,polycarbonate,PVC sheet,composite and layered composite substrates,and HDU solid-block substrates; all of which be can be used in a host of applications.

Michelle M.White,technical applications manager at Vycom Plastics,Scranton,Pennsylvania,says that developments in CNC router technology over the past decade have definitely had a huge impact on the sign market and the jobs that shops can now produce.

There are more routing product options out there than ever before with more precision finishing features such as knife cutting, laser cutting and routing all in one,”she comments.

“This trend has led to faster CNC router cutting solutions being used to fabricate a wider variety of substrates with quicker turnaround times. Based on the feedback from some of the sign shops we work with, expanded foam PVC, polycarbonate, styrene and acrylic seem to be the most popular choices for projects as we move into 2016,”White adds.

More Rigid Options
Patrick Mikes, marketing coordinator at Denco Sales, a wholesale distributor based in Denver, adds that the most common substrates he is seeing being used are HDU, aluminum, brass, other metals, PVC, acrylic, engraving stock, polycarbonate, hard/soft woods and Avonite.

These materials can be fully routed (routed through) or engraved (not routed through, but chiseled on the surface). A swivel tool can also be attached to the router, which gives the machine the ability to plot vinyl that is already mounted to a substrate. The vinyl is then weeded out. One of the products that many of our customers use is DUNA HDU, as it provides less dust and a cleaner cut when routed.”

He points out that routers are most commonly used to make dimensional signs that show depth and perspective. He says that some common types of dimensional signage include: push-through signs, backlit signs, raised or recessed imagery, prismatic letters (beveled/peaked and contoured).Additionally, routers are used for model making, creating molds and press stencils, and ADA signage.

Still in the Designer's Hands
Mikes explains that although there are more automated cutting options, it still comes down to designer's creativity and skill that ultimately determines the quality of the routed sign.“Most routers will give the designer the rough-cut (basic forms and layouts), but a lot of the finishing is still done by hand. No singular material is most popular or commonly used, as it is the combination of materials that makes up the sign. These materials are chosen based on a client's specifications or the designer's suggestions. For example, a designer that is creating a backlit sign could use a translucent colored acrylic for the base/background of the sign, and they could create a stark contrast by using metals or woods when creating the lettering/graphics in the forefront of the sign. Or, they could use aluminum for the background and raised plastic lettering in the forefront to make the sign pop dimensionally.”

Layered Options
Mikes says a variety of different materials can be used for just one sign, as numerous layers can exist in the sign's layout.“There are so many combinations of materials that determine the overall graphical style of the sign. The most common projects include architectural dimensional signs, retail/storefront signs, corporate signage, way-finding and directional signage, ADA signage, ornate furniture, decorative interior art, and municipal signage,”he adds.

HDU Signage Options
Brad Burnett, HDU sales rep at DUNA-USA Inc., Baytown, Texas, says one of the latest trends he is seeing is their HDU product being incorporated into exterior, lighted signage. “Because HDU can be intricately fabricated into unique dimensional backgrounds and designs, it can be used quite effectively to create cost-effective, high-end signage.”

He points out that HDU has typically been the substrate of choice for businesses offering CNC routed signs, mainly due to the fact that it has no grain and is non-abrasive.

“It's not going to wear a cutting bit down like wood or metal will, and is extremely versatile in regards to design capabilities,” he says.“It's not uncommon to see an exterior, lighted sign, crafted from a combination of MDF, HDU and aluminum. The HDU allows for a high-degree of dimensional customization, while the MDF and aluminum are typically used in reinforcing roles.”

Burnett reports that HDU is most often used to give a sign a dimensional look.

“Another common application is to be used as dimensional letters, which are often added to a flat background made from HDU or another substrate such as wood or metal,”he says.

Burnett adds that many types of signs can incorporate HDU into them to add a visually pleasing dimensional look: Monument signs, channel letters, fascia signs, hanging signs, address plaques, and even golf course signage.“It's also popular for HDU to be used as a‘master mold’to create vacuum-formed sign faces. Our newest product is the DUNABOND line of HDU adhesives. The single-part, polyurethane adhesives are both waterproof and can be used to bond HDU, wood, metal, concrete, and other expanded materials together.”

Standing out From the Crowd
Brandon Wyatt,marketing manager,3A Composites USA,Statesville, North Carolina,reports that more and more retailers are focused on differentiating their brand through intricately designed signs and graphic displays.“To create these unique looks, designers and fabricators continue to turn to lines of rigid substrates that have trusted reputations for producing clean, quality cuts with CNC routers, including: our heavy-duty Gatorfoam foam-centered board, Sintra PVC board and Dibond aluminum composite material.”

He explains that heavy-duty Gatorfoam foam-centered board; Sintra PVC board and Dibond aluminum composite material remain popular with fabricators who rely on these durable, rigid substrates because they are well suited for clean routing.“These three rigid substrates offer fabricators a range of price points and physical characteristics designed to meet varying customer needs for the length of time as well as the location that signs will be displayed.”

“Dibond aluminum composite material offers the greatest durability in creating permanent exterior storefront signage. Sintra (in the 6mm and greater thicknesses in the Bright White, Black, Gray and Light Gray colors) also may be used to create exterior signage. Additionally, Gatorfoam (in the 1 inch and greater thicknesses) may be used outdoors provided that the board's edges are painted to protect the sign from UV exposure.”

Smart Products from 3A Composites
Wyatt says that 3A's SMART-X and KAPA tech products are two new easy-to-route rigid premium substrates originally introduced by 3A Composites in Europe and were recently rolled out in the United States.

“SMART-X is a premium quality distinctive lightweight foam board consisting of an all-plastic sheet that is uniquely constructed with a moisture-resistant expanded polystyrene core and two layers of UV-resistant solid polystyrene. SMART-X can be installed outdoors without experiencing any significant change in color for a period of up to two years. It can be direct-digital printed and is easily routed and milled for sign and displays.”

He says that KAPA tech is a hybrid graphic display board that combines the lightweight characteristics of a foam board with the durability of an aluminum composite material—two pre-painted sheets of .008-inch aluminum bonded to a polyurethane foam core.

“This hybrid construction allows KAPA tech to perform in both indoor and outdoor graphic displays with the durability of an aluminum composite material (ACM) but at half the weight of an ACM,”he adds.

Shop Applications
Vycom's White reports that many of their end users are doing some wonderful things with their products and points that one shop in particular that is doing some interesting work in this area is NGS Printing based in Elgin, Illinois.

“They are using many of our products, including expanded PVC, to decorate a variety of items such P.O.P. displays, video games, pinball machines, kiosks, wire displays as well as a variety of other industrial uses,”she explains.

“We find that expanded PVC is a very economical substrate for many P.O.P.applications and is used extensively at NGS Printing for a variety of components and signage,”comments Mark Landrowski, VP of operations.“Our new state of the art digital print equipment offers the option to print directly onto a wide range of surfaces and media. Our digital solutions are the perfect answer to our client's short-run, quick turn or prototype needs,”he adds.

House of Signs
Frisco, Colorado-based House of Signs specializes in custom-routed and handcrafted 3D signs and unique support structures. They have been designing and fabricating award-winning creations since 1989.

“The CNC machine is one of our favorite tools, and offers such a diverse number capabilities. We just finished installing a new Multi-Cam 3000 with auto tool-changer.This is the Rolls Royce of CNC machines, and we are very excited to push the limits this year and beyond,”states Roger Cox, founder and president.

He reports that the most common substrate they use for milling 3D signs is CoraFoam by DUNA-USA.“After product-testing many high-density urethanes over the years, we have found the quality of CoraFoam to be at the top of our list. Very tight-celled and smooth, this product holds incredible detail while remaining very strong, and doesn't absorb primers and paints like some other HDU products we have worked with in the past. We normally mill a rigid backer for all our signs using ¾-inch MDO plywood. The CNC handles this dense product with ease,” he adds.

PhotoWorksGroup
PhotoWorksGroup,Inc., a large-format graphic solutions provider based in Charlottesville,Virginia,has been creating large-format graphics,exhibits,displays and signs for museums, universities,health care institutions, manufacturers and corporations since 1986.

While PhotoWorksGroup uses all types of media, including fabric and vinyl, Geoff Kilmer, president, PhotoWorksGroup, estimates that three out of every four of the company's projects are produced with rigid substrates. To meet the individual needs of each project, Kilmer frequently turns to the wide array of rigid substrates offered by 3A Composites USA.

“With the addition of our Zünd digital cutter, working with rigid substrates is more efficient than ever. The most common rigid substrate we use is Sintra. It's suitable for a wide gamut of applications, is dimensionally stable, and cost effective. We enjoy being able to gang print to large sheets, then cut out on the digital cutter. It really cuts down the labor cost enabling us to remain competitive and profitable,” Kilmer explains.

“In today's competitive market, you really need some automation such as a digital cutter, to cut down on labor costs. I would rather purchase the premium materials such as Sintra, to insure the client gets the best quality product, and save production costs through good organization, production techniques, and automation. As digital cutters become the norm, I believe it is becoming harder and harder to operate competitively in today's market without one,”he concludes.