What Channel Letters Are Made Of: Aluminum or Outdoor Plastic
The face of a channel letter gets all the attention, but the body (the sides, or “returns”) is what keeps the sign straight, sealed and safe for years of Calgary weather.
We build letter bodies from aluminum or from a specialized high-strength plastic designed for outdoor use. This page explains the difference and how we choose between them for your project.
- Free site visit & measurement
- Design included
- 2-year warranty
- Own workshop in Calgary
What the Letter Body Does
A channel letter is a shallow container. The returns form its walls: they hold the face in place, carry the LED modules, keep out water and snow, and give the letter its depth when you look at it from an angle.
Two materials can do that job well outdoors. Aluminum is rigid and keeps sharp, straight lines on large letters. Specialized high-strength plastic is made for outdoor exposure and resists weather and sun. The best choice depends on the letter size, the shape of your font, the lighting and the location.
Why the Right Body Matters to You
Letters that stay straight
A rigid body keeps long strokes and large letters from bowing, so the sign looks crisp for years.
Protection for the lighting
A sealed body keeps moisture and snow away from the LEDs and wiring inside.
Depth that reads from the side
Returns give the letters a solid, dimensional look to people approaching along the sidewalk.
Colour that matches your brand
Returns can be finished in your brand colour or kept a neutral dark tone so the faces stand out.
Fewer surprises later
Choosing the material for the location up front avoids problems that only show up after a few winters.
Aluminum vs Outdoor Plastic Bodies
Both are used on exterior signs. This is how we think about the choice. The final decision is made for each sign.
| Aluminum | High-strength outdoor plastic | |
|---|---|---|
| Best for | Large letters, long straight strokes, tall signs | Many letter sizes, detailed shapes |
| Rigidity | Very rigid, keeps sharp lines | Rigid enough for exterior letters of suitable size |
| Weather | Does not rust; durable outdoors | Designed for outdoor use and resistance to weather and sun |
| Finish | Painted in your chosen colour | Chosen colour or neutral dark tone |
| How we decide | Size, location, lighting and look | Size, location, lighting and look |
If you have a preference, tell us. And if one material would be a poor fit for your letters, we will explain why before anything is built.
When to Insist on Aluminum
- Very large letters or a sign mounted high on the building
- Fonts with long, straight horizontal strokes that must stay perfectly level
- A design where the returns are painted to match a specific brand colour
Price and What Changes It
Standard front-lit letters start from CAD $12 per inch of letter height, per letter, plus GST, with a black body and a white milky acrylic face. Custom return colours, very large letters and special construction are calculated for your project.
Installation is quoted separately; as a guide, it is about CAD $100 per hour plus GST.
- Letter height and count
- Body material and finish colour
- Lighting style
- Mounting method
Get a first estimate on the channel letter calculator.
Not sure which material your letters need?
Send your logo and the wall size. We will recommend the body material and show you the letters on your facade.
How Your Letters Are Made
After the free site visit and design approval, the letters are made in our Calgary workshop in about two weeks. Each letter is assembled, wired and lit before installation. We handle all the sign permit paperwork: we prepare the drawings, specifications and documents and submit the application on your behalf. If you prefer to apply yourself, you get the complete package from us, ready to submit.
The sign carries a 2-year warranty on the LED lighting, power supply, sign structure, materials and installation.
Letter Body Questions
Both, depending on the project. Bodies are made from aluminum or a specialized high-strength outdoor plastic, chosen for the letter size, design and location.
The plastic we use is designed for outdoor use and resistance to weather and sun. We only use it where it suits the size and location of the letters.
Yes. Returns can be finished in your colour or kept dark so the lit faces stand out.
It can. The standard configuration starts at CAD $12 per inch of letter height, per letter, plus GST; custom colours and construction are calculated individually.