| 1 | Design and Technical Review | CAD drawings, 3D modeling software, photometric layout tools | Artwork is prepared in vector format. The design normally defines sign dimensions, acrylic thickness, LED layout, cable routing, mounting method, power load, and viewing distance. | Confirm dimensions, illuminated areas, letter spacing, fixing points, power requirements, and installation conditions before production. | Approved production drawing, artwork file, bill of materials, and inspection checklist |
| 2 | Acrylic Material Selection | Cast or extruded PMMA acrylic sheets; white, clear, translucent, colored, or frosted surfaces | Common sheet thicknesses: 3 mm5 mm8 mm10 mm | Check sheet thickness, color consistency, surface flatness, light transmission, protective film condition, and visible defects. | Acrylic sheets matched to the approved color, thickness, and sign structure |
| 3 | CNC Routing or Laser Cutting | CNC router, laser cutter, cutting templates, dust extraction system | Cutting tolerances are commonly controlled within approximately ±0.5 mm for standard sign components, depending on size and equipment. Laser cutting is generally used for fine contours, while CNC routing is commonly used for thicker sheets and larger panels. | Verify outline dimensions, corner radii, edge quality, cut-through condition, and absence of excessive melting or chipping. | Accurate acrylic faces, backs, panels, and letter components ready for finishing |
| 4 | Edge Finishing and Surface Treatment | Deburring tools, polishing wheel, flame-polishing equipment, sanding tools | Cut edges may be polished to improve transparency and appearance. Frosted or textured surfaces can be produced by using pre-finished sheets or controlled surface treatment. | Inspect for sharp edges, scratches, haze, burn marks, uneven polishing, and contamination under standard lighting. | Smooth, clean, and visually consistent acrylic parts |
| 5 | Graphic Printing or Film Application | UV flatbed printer, translucent ink, vinyl film, transfer film, laminating tools | Printing may be applied to the front or rear surface depending on the required diffusion and visual effect. Multiple ink layers can be used to adjust opacity and color density. | Check color consistency, registration accuracy, adhesion, pinholes, scratches, bubbles, and print uniformity after curing. | Printed or color-finished acrylic panels with controlled light transmission |
| 6 | Frame and Housing Fabrication | Aluminum or steel frame, acrylic cement, brackets, screws, channels, bending and welding tools | Housing depth is selected according to sign size, LED spacing, optical requirements, and maintenance access. Larger signs generally require additional reinforcement and internal support. | Check frame squareness, structural rigidity, joint strength, drainage provisions, access covers, and alignment with the acrylic face. | Assembled sign cabinet, dimensional lettering, or panel housing |
| 7 | LED Layout and Installation | LED modules or LED strips, mounting adhesive, screws, wiring, connectors, reflectors or diffusion materials | Typical LED systems use low-voltage DC power, commonly 12 V or 24 V. LED spacing is determined by module optics, cabinet depth, acrylic diffusion, and the required brightness uniformity. | Verify polarity, module spacing, wire routing, adhesion, heat dissipation, dark spots, hot spots, and access for replacement. | Evenly illuminated internal LED assembly with organized wiring |
| 8 | Power Supply and Electrical Wiring | Constant-voltage LED power supply, terminal blocks, fuses, connectors, grounding cable | Power supply capacity is normally selected with a design margin of approximately 20% to 30% above the calculated LED load. Input voltage and frequency are specified according to the installation market. | Check output voltage, load calculation, insulation, grounding, wire gauge, terminal tightness, polarity, and cable labeling. | Electrically connected sign with protected and serviceable wiring |
| 9 | Mechanical Assembly | Acrylic face, frame, rear panel, seals, fasteners, mounting brackets, silicone or suitable sealant | Components are assembled according to the approved drawing. Fasteners and seals are selected based on sign weight, indoor or outdoor use, and expected environmental exposure. | Confirm panel alignment, fastening security, gap consistency, surface cleanliness, and protection against moisture where required. | Fully assembled acrylic LED sign board ready for testing |
| 10 | Illumination and Electrical Testing | Digital multimeter, insulation tester, power meter, light meter, controlled test area | Testing normally includes start-up operation, continuous illumination, voltage and current measurement, brightness uniformity, color consistency, and thermal observation. | Check for flicker, dead LEDs, uneven brightness, abnormal noise, excessive heat, voltage drop, and unexpected power consumption. | Tested sign with recorded electrical and illumination results |
| 11 | Environmental and Safety Inspection | Visual inspection tools, water-spray equipment where applicable, grounding and insulation test instruments | Outdoor models may be designed with sealed joints, drainage, protected connectors, and weather-resistant components. The required ingress protection level depends on the installation environment and project specification. | Inspect sealing, drainage, cable entries, grounding continuity, insulation resistance, enclosure condition, and mounting safety. | Sign suitable for the specified indoor or outdoor installation conditions |
| 12 | Final Inspection and Packaging | Inspection checklist, protective film, foam, corner guards, cartons, wooden cases or export pallets | Final inspection covers appearance, dimensions, artwork, illumination, accessories, labels, installation instructions, and quantity. Fragile acrylic faces are protected against impact and abrasion. | Confirm product code, quantity, accessories, test records, package strength, and shipping marks before dispatch. | Packed acrylic LED sign boards prepared for domestic or international delivery |