Before producing LED illuminated letters (specifically those with exposed LEDs), let us first look at the basic materials involved: acrylic sheets, galvanized steel, stainless steel, titanium-plated sheets, etc.
The production process for LED illuminated letters (exposed LED type) is as follows: 1. Punch holes in the full sheet of material using a machine (hole diameter is determined by the size of the LEDs); 2. Weld 3D side walls onto the cut-out letter shapes (similar to the method used for baked-enamel letters); 3. Sand the edges and corners to remove any burrs; 4. Apply a baked-enamel finish; 5. Install the LED lights. There are two methods for this: A. An older method (low material cost but high labor) involves connecting individual bare LEDs one by one, calculating the current, and sealing them with adhesive for waterproofing—this method is prone to issues; B. A widely used modern method (higher material cost but lower labor) utilizes pre-assembled LED strings where each bulb is already waterproofed with a rubber sleeve—these are readily available on the market, easier to maintain, and offer greater reliability.
1. Power calculation for LED vacuum-formed illuminated letters: Generally, the formula is Quantity × 0.24W = Power. While various power supplies approximating the required specifications are available on the market, one should select products from reputable manufacturers and ensure the power supply is waterproofed; 2. When calculating power, account for potential line loss and never overload the power supply; typically, only 70% of the rated capacity should be utilized; 3. Be aware that power supplies on the market often do not deliver their full rated power.
Key features of 3D LED illuminated letters: 1. Bright and eye-catching at night (utilizes a new type of ultra-bright light source with a long lifespan, allowing the acrylic sheet to emit a dazzling glow); 2. Strong 3D effect (the thicker the side walls, the more pronounced the 3D appearance); 3. Vivid colors (wide selection of acrylic sheet colors; side walls and face panels can be combined in any color scheme). Production method for LED illuminated letters: Step 1 >> Calculate the number of LED modules: Arrange them at equal intervals and simulate the distribution on a computer to make a preliminary estimate of the required quantity. Module spacing should be between 3–6 cm depending on brightness requirements, and the letter thickness can range from 5–18 cm. Step 2 >> Calculate total power consumption and select a power supply: Estimated number of LED modules × power per module = total power consumption. It is recommended to allow for a safety margin in the power supply selection, utilizing it at 80% of its rated capacity. Choose between standard or waterproof power supplies based on the operating environment. Step 3 >> Install modules: ① Clean the mounting surface; ② Apply double-sided adhesive to the bottom of the modules; ③ Arrange evenly and connect wiring; ④ Install the letter face panel and test the effect; ⑤ Final product.
I. Features of waterproof LED string lights: 1. Multicolor (RGB) LED string lights: Fully leverage the advantages of LED point light sources; they can be combined in any configuration, simplifying the production of exposed-LED letters, large outdoor LED signage, and LED electronic light boxes. 2. Special snap-fit design: Allows for direct installation after drilling holes, ensuring rapid setup. 3. Compatible with various panel materials: Suitable for drilling into electrolytic plates, aluminum-plastic composite panels, iron sheets, stainless steel plates, etc. 4. Uses premium LED chips: Ensures product quality through high brightness, consistent light color, excellent color saturation, long lifespan, and low light decay. 5. Parallel wiring configuration: Eliminates the traditional drawback where the failure of a single light causes the entire string to go dark. 6. Full-color string lights (Multicolor series): Utilize an intelligent control system to produce effects such as gradients, jumps, chasing/scanning patterns, and animated graphics/text. They support both asynchronous and synchronous control and offer flexible arrangement options to meet diverse user requirements. II. Specifications for Color-Changing (RGB/Dream-color) LED Light Strings for Exposed-LED Signage: 1. Operating voltage: DC 5V, DC 12V, or DC 24V. 2. LED light string colors: Red, yellow, golden yellow, blue, green, white, purple, orange, dual-color, multi-color, or full-color (RGB).
III. Applications for Waterproof LED Light Strings: Using color-changing LED light strings for outdoor illuminated lettering and signage highlights brand identity and style, significantly elevating the business's scale and prestige. Primary applications include: large rooftop signage, hotel outdoor signs, signage for entertainment venues (such as KTVs), storefront signs, and entrance signage.
IV. Fabrication Steps for Exposed-LED Signage: 1. Tools required: 40W or 60W soldering iron, solder, electric drill, glue gun, screwdriver, etc. 2. Additional materials required: Perforated metal letters, electrical wiring, and a power supply unit compatible with the color-changing LEDs. 3. Perforation: Determine hole diameter (e.g., 5mm, 9mm, 12mm) and spacing based on installation height and budget. Typical center-to-center LED spacing ranges from 10mm to 30mm; closer spacing results in higher brightness but also higher costs. 4. LED Installation: Clean the drilled holes and insert the LED lights one by one. 5. Wiring: Use pre-wired waterproof LED strings. Connect the reserved wire leads—typically connecting the red wire to the positive terminal and the black wire to the negative terminal of the dedicated LED power supply. The power supply unit should be housed in a protective enclosure. 6. Testing and Burn-in: After connecting all LEDs, identify and fix any non-functional lights, then conduct a 48-hour burn-in test. 7. Transport to the site and erect scaffolding for on-site installation.
V. Usage Precautions: 1. Color-changing LED light strings operate on DC5V, DC12V, or DC24V; please ensure you use the correct voltage type. 2. The cross-sectional area of the wire leading from the power supply must be at least 4 mm² (alternatively, two 2.5 mm² wires may be used). 3. Connect the red wire of the light string to the positive terminal of the power supply (in some cases, there are two wires; connect them in parallel before connecting to the positive terminal). 4. Connect the black wire of the light string to the negative terminal of the power supply (in some cases, there are two wires; connect them in parallel before connecting to the negative terminal). 5. If individual lights fail to illuminate, check the lights or wiring; if they still do not work, replace the LED unit. 6. Dual-color and RGB (full-color) waterproof exposed LED strings utilize a common-positive configuration, with the controller managing the negative side. 7. For full-color waterproof exposed LED strings, the four-wire configuration is as follows: red is positive, followed by negative, data, and clock lines. 8. Calculation method for production costs:
Calculated based on "nominal area" (or "virtual square meters"). What is nominal area? Here is an example: Suppose you want to fabricate a character that is 80 cm high and 60 cm wide. The area is calculated by multiplying the character's maximum stroke dimension by 1. Based on these dimensions, the area is 0.8 square meters (rather than the actual 0.48 square meters). Then, multiply this by the unit price. This calculation method applies only to characters under one meter in height; the method differs for characters larger than one meter.
For example, for a character 1.2 meters high and 0.9 meters wide, the calculation is based on the square of the maximum stroke dimension—meaning 1.2 m × 1.2 m = 1.44 square meters. Be sure to calculate this accurately when fabricating copper or sheet-metal characters. Additionally... Especially when the signage is to be installed at a significant height, you should verify whether there is an additional fee for high-altitude installation and, if so, who is responsible for covering it. Generally speaking, the larger the characters, the higher the unit price; this is because larger characters involve wider strokes, which places greater demands on the materials used. It is worth keeping this in mind.
