Custom Wooden Letters - Material Explanations

Custom Letters by Texas Shirt Company

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Ordering custom letters for your special project can be frustrating, confusing, and downright irritating. It doesn't have to be and I'd like to help you have a better understanding of the different materials used in making letters. This article is organized into sections based on how you use the materials, what the advantages and disadvantages of each material are, and a word or two about the process.

Material Uses: For every use there is an ideal material. It's very important that you choose the right material so that the letters last and do their job for a long time. The most important factor to consider is where you are going to put the letters. Outside is hard on wood in particular and not nice to most materials in general. From boiling to freezing and everything in between the letters have to stay put and not warp or disintegrate. This calls for acrylic, solid wood, or 1/4" or thicker plywood. When you use wood it's important to seal it with a good quality paint or finish. Wood letters are not recommended for two-sided applications where they can be viewed from both sides. Front cut finish is guaranteed, back finish is not. Backside is considered sacrificial and may have material missing, burn marks from laser machining, or process marks.

Advantages and Disadvantages:

1/8" thick Birch Plywood - Great for interior use, art projects, and light usage. Not recommended for outdoor use. Very lightweight and excellent for incorporation into mixed media such as greek paddles, signs, scrapbooks, and more. Can be glued into place with little effort. Will deteriorate in outdoor usage if not sealed properly. Glue in this plywood is not outdoor rated.

1/4" thick Birch Plywood - A sturdy, durable material that lends itself well to indoor and protected outdoor usage. Great when you need a letter that will go the distance and look nice. This material is very strong and has a nice surface vaneer that finishes well and accepts stain. This plywood is not made with a outdoor glue. It must be protected from the elements and well sealed or it will deteriorate. Variations in glue in this plywood cause the cut to be rougher than in other materials. Product is supplied rough finished and will require some sanding, occassional trimming.

1/4" thick MDF - Medium Density Fiberboard is a economy alternative to 1/4" Birch Plywood. It accepts paint and stain well but is not recommended for outdoor use. This is an indoor only material. Exposure to moisture may result in the material decomposing, becoming unglued, or expanding and warping. This is great for indoor uses where you want the look and thickness of plywood but need a less expensive material.

Clear or Colored Acrylic - Like all plastics, acrylic is nearly invinceable. It may accept some paints. We do not recommend nailing this material. It is available in a range of thicknesses from 1/32" to 1/4". Call with questions about colors as the material isn't uniformly available in all colors and thicknesses. It's chief advantages are that it is durable and won't absorb moisture. It can be used indoors or outdoors but will eventually age.

Call with questions please.
Please have reasonable expectations about wood. Wood is a natural product and variations in color, density, glue, and grain are normal.
Some woodworking skill is necessary. You will need to sand the edges at a minimum. Letters are supplied "rough finish" and require sanding. We do inspect them prior to shipping. Most letters are completely fine. 1/4" Birch may require additional trimming. This can be done with diagonal pliars, a hack saw, or file. Variations in the plywood glue cause inconsistent cutting and are unavoidable in all plywoods.