How Are 3D Built-Up Letters Made: A Step-by-Step Guide

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Close up of Built Up Letters during Sign Production at Fabricut

We Love 3D Built-Up Letters

Imagine a world without signs – what a confusing and disorienting place it would be. From bustling city streets to charming countryside towns, signage guides us, informs us, and captivates us. When it comes to creating visually appealing and high-impacting signs, built-up letters take center stage.

1: Understanding Built-Up Letters

Ah, built-up letters – the unsung heroes of the signage world. These three-dimensional wonders add depth, character, and sophistication to all signs. But what exactly are built-up letters, you ask? Well, they are individually crafted 3D letters, (or 3D logos) and can be made from a variety of materials including sturdy metals like stainless steel, aluminium, or brass, as well as acrylic and PVC.

Built Up Rimless Sign by Fabricut

2: Designing the Sign

Next, let’s dive into the creative process. Professionally designing a sign involves a lot more than just picking a pretty font (although that’s important too!). The initial design stage requires careful consideration of the sign’s layout, typography, desired message and its proposed location.

Choosing the right fonts, colours, and sizes for the built-up letters is crucial, as they must all harmonise with the sign’s location and purpose. It’s all about creating an eye-catching masterpiece that truly speaks to its audience. As professional sign makers, we’re usually supplied with a set of official Brand Guidelines to follow from the client.

3: The Fabrication Process

The artistry of fabrication. Follow us step by step as we unveil the (simplified) process of bringing built-up letters to life:

  • 3.1 Material Selection and Preparation
    Each material chosen has unique qualities and aesthetic appeal. Whether it’s the timeless elegance and of metal, or the versatility of acrylic, our skilled manufacturing team carefully select and prepare the materials to ensure the best final outcome.
  • 3.2 Cutting The Letters
    Precision is the name of the game here. Our expert technicians employ cutting-edge tools and state-of-the-art CNC machines to cut out the letters with incredible accuracy.
  • 3.3 Bending and Shaping
    To achieve that high-impacting three-dimensional effect, the letters are skilfully bent and shaped. This is either done by machine, or via very skilled and experienced hands. It’s like watching a sculpture take form before your very eyes.
  • 3.4 Welding or Bonding
    Assembling the 3D letters requires particular finesse and expertise. The letters are seamlessly welded or bonded together to create a cohesive and durable three-dimensional sign that will stand the test of time.
  • 3.5 Smoothing and Sanding
    On to the finishing touches. Like a master painter preparing his canvas, we smooth and sand the built up letters to perfection, ensuring a surface that radiates quality and professionalism.

4: Finishing Touches

A sign is not just about the letters; it’s about the complete package. The finishing touches are what truly make a sign pop. From painting and powder coating to applying eye-catching vinyl wraps, the final finishing possibilities are endless.

At Fabricut, we never forget the importance of quality control. Each letter is painstakingly inspected to ensure it is free from imperfections, guaranteeing our clients of a flawless and successful end result.

5: Installation and Maintenance

With a sign’s fabrication complete, it’s time for installation. Different surfaces require different techniques, whether it’s mounting the letters on a façade, or affixing them to interior walls. Our team of expert fitters can install your sign or provide your own fitters with an installation guide.

Remember, maintenance is key! Regular cleaning and care will ensure that your sign remains vibrant and captivating year after year. After all, a well-maintained sign is a sign of a well-kept business. Read our top tips for sign maintenance.


As we wind-up this (simplified) step-by-step guide on the art of creating built-up letters for signs, we hope you have gained an appreciation for the craftsmanship and expertise involved. These letters transform signs into captivating works of art, conveying messages with elegance and visual impact.

So, whether you’re a sign maker seeking to outsource your 3D signage manufacturing, or a design agency searching for a full trade signage partner, give us a call. At Fabricut, we stand ready, with our West London heritage and nationwide convenience, to offer you our expertise, quick turnaround times, and comprehensive services.