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Epoxy Resin Channel Letters VS. Acrylic Face-lit Letters

Epoxy resin channel letters

Table of Contents

What are Epoxy Resin Letters ?

Epoxy Resin channel letters are made of epoxy resin face, metal returns, and inner LED lighting. It is a common advertising sign used in shops, branding chain stores, front door signs, etc.

The appearance of Resin letters is similar to opal acrylic face-lit letters. What is the difference between them? How to make the perfect epoxy resin letters? What are the advantages and disadvantages of epoxy resin channel letters? In this article, we discuss more details about the epoxy resin letters.

How to make Epoxy Resin Letters ?

1. Fabricate the letters returns and base

Cut out the letters’ sides, based upon the layout, and weld to 3D channel letters shape.

The material for the letters is commonly stainless steel (Polish or brushed).

To get smooth and perfect letters with fantastic lighting effects, first, we use grinding tools to remove the rust and burrs on the steel surface. Then we need to paint white on the interior wall of signs to reflect the LED illumination to the face.

2. Install LED lighting

The lights usually use LED strips which are ultra-thin, ultra bright.

3. Spray painting

Polish the letter’s case, and spray paint on the side. More details about spray painting, please find in this article.

4. Pouring the first layer of clear epoxy resin

To avoid the epoxy liquid leak into the LED strips, we place an acrylic plate above the LED and use the glue gun tightly sealed.

Then pour the resin liquid onto the acrylic plate; the thickness of the pouring resin layer is about 20mm, and it stops flowing when it is 5 mm away from the top of the letters. As it is clear, we call it a light guide layer.

This layer reflects the light exposure at the bottom into the light guide plate to improve light utilization efficiency.

Pour the resin layer

5. Pouring the second layer of epoxy resin

When the first light guide layer turns into a solid, we pour the second layer, called the diffuse layer, to fill into the top.

The formal is resin, curing, color paste, and leveling agent.

This layer diffuses the linear light emitted by the LED on the light leveling layer so that the entire surface of the luminous characters can be evenly illuminated, and the bright spots of the LED inside cannot be seen.

Pouring resin is a critical step for making the epoxy resin channel letters. During the operation, we clean the room, equip a thermostatic device, use a clean container for resin liquid, wear disposable gloves to work, and wear shoe covers too.

The pouring process should be done in one go.

6. Solidify

The resin liquid turns naturally into a solid in 4-6 hours at a constant temperature and 8-10 hours at an average temperature.

7. Clean the finishing letters and lighting aging

Clean the extra resin overflowing outside the letter’s sides and age the light source to prolong the letter’s lifetime.

Epoxy Resin Letters VS. Acrylic Face-lit Letters

Epoxy resin letters are a front-lit advertising sign letter, and acrylic front-lit letters are illuminated on the face too.

What’s the difference between them? We make a comparison of the aspects in the following elements.

  • the appearance
  • the performance
  • the production cost
  • the maintenance cost
Sign typeEpoxy resin lettersAcrylic face-lit letters
Refer picture
Face Materialsepoxy resinopal acrylic
Face appearanceflat and sealed wellflat, types of trimless and trim cap
Colorvarious colours,
vinyl applied on the face is available
various colours,
vinyl applied on the face is available
LEDVarious colorsVarious colors
Font strokes thin strokes letters is availablethin strokes have a higher risk of being broken,
and they have dark spots in the corner
Sealingtightly sealed with epoxy resinTrimcap less types will see the light from side
Face open
Product Costa bit cheaperaffordable
Life Spaninterior use,
easy fade or change color exposed
in the sun or rain
exterior and interior use,
corrosion and oxidation resistance
Maintenance feeDifficult to repair,
as the resin filled in the case
Easy to repair,
loose the grub screws and open the case
Epoxy Resin Letters Vs. Acrylic Face-lit Letters

Advantages and disadvantages of epoxy resin letters



Resin channel letters come in a wider range of color resin paste and LED strips, which brings various color appearance and multi-color illumination.

Two resin layers have different functions to diffuse the inner LED light, illuminating it brighter.

Smooth surface and excellent sealing

Epoxy resin has the lowest curing shrinkage rate, limited to 1%-2%. Therefore, the resin faces have stable dimensions, minor internal stress, and are not easy to crack.

The face is tightly sealed with a stainless steel case, with no trouble of light leaking from the side of the face and no extra resin parts visible outside too.

Suitable for thin strokes letters

If the corner of the letters is thin strokes, resin letter is a great option. The resin liquid can flow and fill the corner well, no matter how small the strokes.

While for the acrylic face-lit letters, the thin strokes have a higher risk of being broken, and they have dark spots in the corner.

Resin letter suitable for thin strokes letters

Affordable production cost

Compared with acrylic face-lit letters, resin letters have a cheaper production cost.

No limits on the letter size

The regular size of one piece acrylic sheet is 1200*2400mm. It is only workable for large-size letters if we customize the suitable size acrylic sheet.

Unlike the acrylic sheet, resin faces do not limit the letters’ size and get beautifully crafted letters.


Not suitable for outdoor

Resin letters are moisture-proof, waterproof, and anti-corrosion, but it is not recommended to install them outdoors because they will turn yellow under long-term sunlight exposure.

High maintenance cost

The resin face is solid with the steel case, and we cannot open the beginning easily like the acrylic face. If the inner LED is not lit, the only maintenance method is to remake a new one.

white resin letters

Take away

Epoxy resin channel letters have brought a new type of face-lit letters since 2008; the various color options, brighter led illumination, and beautiful appearance attract us to them in our interior signage project.

As a team of signage specialists, FT signage understands the epoxy resin channel letters-making process and international export rules.

All components of advertising signs have passed ROHS, CE, and UL certifications to assure quality and safety.

Welcome to take advantage of our custom signage supply service, and discuss further with us.

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