Martin Lemiesz, Managing Director at Lemon Signs Ltd, has been pioneering a new way of building 3D letters. The process starts with the insertion of
a sheet of plastic extruded film, then the de- sign file is sent through, and the printed lay- ers are cut and glued together to build the letters. The materials are cut using a hot wire cutter as opposed to a CNC machine, and they are then filled using a special type of foam. “The foam used inside is similar to the foam used to insulate buildings, really light and really strong,” says Martin. “We then paint it either for external or internal use, and glue all parts of the sign together. We are still testing various glues to see which has the best results. We have a couple of test letters outside in the elements now to compare and see which works best.” Letters are finished using an epoxy
resin or durable outdoor lacquer to prolong the lifespan, which is on average about seven years, at which point the letter’s exte- rior should be recoated. “In terms of the in- ternal foam, that should last virtually forever,” says Martin, adding that they are still playing around with ideas for halo illumination and other types of lighting.
A new era for built-up lettering This method is popular in United States as well as Poland, the latter being the origin of the machine used to create the letters. “The climate there is much harsher than that of Britain, but they use that method because it’s cost-effective. The fact that letters have been tried and tested in harsh winters and hot summers proves that they can withstand the elements, so all we need to do now is con- vince people here that it’s a very good alter- native to the traditional methods.”
"A foam built-up sign for Chealsea Football Club". The foam letters can cost up to 50%
less than these traditional methods, and the turnaround time is much quicker than producing something in steel for example. In fact, Lemon Signs completed one project within five days of the initial idea
being discussed. In addition to the lower cost, there is also the lower weight of the letters as an added benefit. “In terms of health and safety, I imagine the weight is about one tenth of a traditional built-up letter,” he says.
The Wilkinsons built-up letters are on display in Head Office. Lemon Signs have completed a num-
ber of high-profile projects using this new method, including signage for the high street brand Wilkinsons. This project involved sup- plying numerous 3D logos for their exhibi- tions and conferences, with one now on display in their headquarters. While the team continues to hone the
new technique, they are convinced that it boasts numerous advantages and options for the future. But first, clients need to be won over. “People can be hesitant about the method as they’ve never seen it before,” says Martin, “so it takes a bit of effort to drop some samples off and explain the process. However, once people see it’s a really light- weight product, lighter than say a traditional stainless steel or extruded plastic letter and yet still the same quality, they’re convinced.”
The foam-filled letters cut with hot wire as opposed to CNC are new to the market.
www.lemonsigns.com ISSUE 160 NOVEMBER/DECEMBER 2015 Sign Update 47
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