Aluminium letters, light enough to go high.
When a fascia is long, high or has to carry its own weight on a slim frame, aluminium does what steel cannot — it stays rigid at a third of the weight, and it takes any colour you want.
Why aluminium, and when not to
Aluminium weighs roughly a third of stainless steel for the same letter. On a 40 ft fascia that difference decides whether the wall needs a structural frame or just anchors. It also never rusts — it oxidises to a stable skin instead — which makes it the safer choice on coastal buildings when the budget will not stretch to SS 316.
Where it loses: aluminium cannot be polished to a true mirror, and a dented aluminium face is harder to bring back than steel. For a small reception sign at eye level, steel is usually the better buy.
Finishes
- Powder coating — any RAL shade, matte or gloss. Oven-cured, so it does not chip like spray paint. This is what most brand colours are matched to.
- Anodising — the colour goes into the metal rather than sitting on it. Silver, champagne and black are standard. It survives abrasion far better than paint.
- Brushed and clear-coated — a natural aluminium look for industrial and architectural work.
Types we fabricate
Fabricated channel letters
Face and return cut separately, folded and riveted or welded, then coated as one piece. This is the standard build for illuminated signage — the hollow inside carries the LEDs and wiring.
Flat cut letters
Routed from 3 mm, 6 mm or 10 mm solid plate. No hollow inside, so no lighting, but the edge is crisp and the letter is almost indestructible. Good for entrance gates and boundary walls.
ACP fascia with aluminium letters
The composite panel forms a flat, shadow-free background over a galvanised frame, and the letters are pinned clear of it. On an old or uneven wall this is often cheaper than repairing the wall.
Typical uses
- Long retail and mall fascias where weight matters
- Building-top and parapet signage
- Industrial sheds and factory gates
- Anything that must match an exact brand colour
- Coastal sites on a tighter budget than SS 316 allows
Common questions
Are aluminium letters cheaper than stainless steel?
Usually yes — aluminium sheet costs less and is faster to work. The gap narrows on powder-coated letters because coating is an extra process, and disappears on very small letters where labour dominates.
What thickness is used for aluminium letters?
Fabricated letters use 2 mm to 3 mm for the face and 1.5 mm to 2 mm for the return. Flat cut letters are routed from 3 mm, 6 mm or 10 mm plate depending on the size and how far they stand off the wall.
Will powder coating fade in the sun?
Good powder coating holds its colour for years, but strong reds and yellows fade first anywhere in India. For a south-facing fascia in a brand colour, anodising or a PVD-coated steel letter lasts longer.
Can aluminium letters be made large?
Yes — that is where aluminium is at its best. We have fabricated letters over 6 ft tall. Above roughly 3 ft the letter is built with internal ribbing so the face does not oil-can in the wind.
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Get a costed estimate today
Send the sign width, the material you have in mind and a photograph of the wall. That is usually enough for us to quote.