We check the artwork
Lux reviews the design at the intended size, measures the narrowest strokes and checks tight gaps. If the size is still open, we can help you choose one.
Channel Letter Stroke Width & Size Guide
Trade production guide
Channel Letter Stroke Width & Size Guide
Lux Signage Co. provides white-label channel letter production support for U.S. sign shops. Send a logo, sketch, photo or rough brief and we’ll check the stroke tolerances and recommend a build.
Size and depth reference
Compare channel letter construction
These overall letter height ranges and suggested depths are a planning reference. Millimeters are the reference values and inches are rounded. Lux handles the artwork and feasibility review when you send us the project.
Front-lit channel letters
Choose the face and edge detail that suits the artwork.
| Construction | Light direction | Overall letter height | Suggested build depth |
|---|---|---|---|
| Trimless front-lit | Front face | 50–1200 mm 1.97–47.24 in | 30, 60, 80 mm 1.18, 2.36, 3.15 in |
| Aluminum and plastic trim cap | Front face | 150–1200 mm 5.91–47.24 in | 60, 80, 100, 120 mm 2.36, 3.15, 3.94, 4.72 in |
| Trim-cap front-lit | Front face | 150–3000 mm 5.91–118.11 in | 60, 80, 100, 120 mm 2.36, 3.15, 3.94, 4.72 in |
| Front-lit with integrated retainer | Front face | 100–3000 mm 3.94–118.11 in | 60, 80, 100, 120 mm 2.36, 3.15, 3.94, 4.72 in |
| Perforated front-lit | Through perforations in the face | 200–3000 mm 7.87–118.11 in | 30, 50, 80, 100 mm 1.18, 1.97, 3.15, 3.94 in |
| Vacuum-formed front-lit | Front face | 200–2800 mm 7.87–110.24 in | 60, 80, 100, 120 mm 2.36, 3.15, 3.94, 4.72 in |
Halo, side and dual-lit letters
Select where you want the light to appear.
| Construction | Light direction | Overall letter height | Suggested build depth |
|---|---|---|---|
| Halo-lit / reverse-lit | Rear halo | 50–3000 mm 1.97–118.11 in | 20, 30, 50, 80 mm 0.79, 1.18, 1.97, 3.15 in |
| Side and back-lit | Sides and rear halo | 50–1200 mm 1.97–47.24 in | 30, 45, 60 mm 1.18, 1.77, 2.36 in |
| Dual-lit channel letters | Front face and rear halo | 100–2000 mm 3.94–78.74 in | 60, 80, 100 mm 2.36, 3.15, 3.94 in |
Acrylic, resin and neon-style letters
Compare compact acrylic profiles and specialty lighting effects.
| Construction | Light direction | Overall letter height | Suggested build depth |
|---|---|---|---|
| Mini acrylic with face and edge glow | Front face and edges | 100–800 mm 3.94–31.5 in | 20, 25, 30 mm 0.79, 0.98, 1.18 in |
| Mini acrylic with edge glow | Edges | 100–800 mm 3.94–31.5 in | 20, 25, 30 mm 0.79, 0.98, 1.18 in |
| Mini acrylic with face and edge glow, alternate build | Front face and edges | 100–800 mm 3.94–31.5 in | 20, 25, 30 mm 0.79, 0.98, 1.18 in |
| Fabricated all-acrylic, edge-lit | Edges | 100–1500 mm 3.94–59.06 in | 60, 80, 100 mm 2.36, 3.15, 3.94 in |
| Fabricated all-acrylic, face and edge-lit | Front face and edges | 100–1500 mm 3.94–59.06 in | 60, 80, 100 mm 2.36, 3.15, 3.94 in |
| Epoxy resin letters | Front face | 50–1000 mm 1.97–39.37 in | 20, 30, 60 mm 0.79, 1.18, 2.36 in |
| Acrylic faux neon | Illuminated contour | 100–1500 mm 3.94–59.06 in |
Front section 10–30 mm 0.39–1.18 in
Rear section 15–30 mm 0.59–1.18 in
|
| Flex neon | Illuminated contour | 100–1500 mm 3.94–59.06 in |
Front section 11–15 mm 0.43–0.59 in
Rear section 6–10 mm 0.24–0.39 in
|
Non-illuminated dimensional letters
Choose a solid cutout, fabricated letter or sculpted profile.
| Construction | Light direction | Overall letter height | Suggested build depth |
|---|---|---|---|
| Solid flat-cut letters | Unlit | 10–500 mm 0.39–19.69 in | Varies by material |
| Fabricated dimensional letters | Unlit | 50–3000 mm 1.97–118.11 in | 8–300 mm 0.31–11.81 in |
| Sculpted 3D dimensional letters | Unlit | 200–2000 mm 7.87–78.74 in | 30, 50, 80, 100 mm 1.18, 1.97, 3.15, 3.94 in |
Depth is listed for the sign body or for each section on two-part profiles. Lux checks mounting clearance as part of the project review.
Artwork feasibility
What is the minimum stroke width?
Lux determines the minimum workable stroke for each design. We check the artwork at the intended size and review the material, lighting and construction. Thin serifs, narrow logo elements and tight inside corners can change what is feasible. Send whatever you have and we’ll do the checks for you.
We work through the build
Lux checks what the lighting, materials and mounting require. If the original design needs an adjustment, we explain the options and recommend a construction that preserves the look you’re after.
Completed Lux projects
See how Lux handles real channel letter jobs
See how Lux handled a small emblem, a visible raceway finish, and wiring for individual halo-lit letters.
Small halo-lit logos
Two 9-inch-wide hockey emblems used 304 stainless steel and acrylic with a 1.5-inch body depth. Lux coordinated the lighting spec with the other signs in the package.
Front-lit storefront letters on a raceway
For this 15-foot exterior layout, Lux documented four raceway sections and revised the visible raceway color to better match the storefront. The project includes a redacted production specification.
Halo-lit letters with individual leads
Lux carried the 60-inch layout into a revised drawing and confirmed approximately 6.5 feet of lead from each letter during the handoff.
For sign shops
Can my sign shop outsource channel letters and keep the customer?
Yes. Lux Signage Co. supports sign shops with white-label channel letter production. Your shop keeps the customer relationship, sets its resale price and coordinates local installation. Lux works with your team on artwork review, build specifications, fabrication and shipping.
Send what you have
Start with a logo, photo, sketch or rough brief. Lux checks narrow strokes, tight gaps and lighting requirements. If a detail needs to change, we explain the options and how they affect the look.
Review the proposed build
Lux provides project-specific wholesale pricing and a build file covering dimensions, materials, finish, lighting and mounting. Your team reviews the details before fabrication starts.
Review the finished sign
Lux coordinates fabrication, shares finished photos for quality review and provides shipment tracking. Your shop stays the point of contact for its customer.
How Lux works with trade partnersSee the quote-to-delivery process
Trade questions
What Lux handles for your shop
Can Lux make narrow-stroke trimless channel letters?
Yes. Send whatever artwork you have. Lux checks the narrowest stroke, face retention, returns and lighting clearance and recommends a workable build.
Can Lux quote small halo-lit letters and logos?
Yes. The halo-lit profile has an overall letter height planning range of 50–3,000 mm. Actual feasibility depends on the narrowest stroke, spacing, material and mounting surface. A completed Lux project used 9-inch-wide, 10.9-inch-high stainless steel halo-lit emblems with a 1.5-inch body depth. Send what you have and Lux will check your design.
What if the artwork is too fine for the requested build?
Lux will recommend a fix and walk you through it. Depending on the design, that may mean increasing the finished size, adjusting a few strokes, opening tight gaps or changing the lighting profile.
Can I start with a sketch or an incomplete brief?
Yes. A logo, sketch, photo or rough description is enough to start. If you already know the size, quantity or finish, feel free to include it. Lux will guide you through the rest.
Have a tight stroke or a small logo?
Send whatever you have. Lux will handle the stroke checks, tolerances and construction review, then help your shop quote the job.