Metal letters say permanent. On a lobby wall, a storefront or a building entrance, they look solid, catch the light and last for years. They also come in more types than most people expect, and the right choice depends on where they go and how close they sit to salt and weather.
Gogi Signs makes and installs metal letters for businesses across New Jersey and New York City. This guide covers how metal letters are made, which metal to choose, finishes that last and the rules in NYC.
In this guide
Where Metal Letters Work Best
- Lobby and reception walls. Brushed or polished letters behind the front desk. See our lobby signs.
- Storefronts and entrances. Unlit or halo lit letters on the facade.
- Glass walls. Letters mounted on glass or a standoff panel.
- Historic buildings. Metal letters suit older facades better than plastic.
How Metal Letters Are Made
- Cast. Made by pouring molten bronze or aluminum into a sculpted mold, with a solid front and hollow back, in sizes from 2 to 64 inches. Gemini says cast letters endure indoors and outdoors and can be halo lit, on its cast metal overview.
- Flat cut. Cut from flat sheets of metal with lasers, CNC routers and waterjets, with finishes from paint to hand polished sheens and patinas, according to Gemini’s flat cut overview.
- Fabricated. Built from metal faces and sides, so they can be large, deep and hollow, and can hold LEDs for halo lighting.
Choosing the Metal
- Aluminum. Light, rust free and easy to paint. The most common choice.
- Stainless steel. Brushed or polished. Type 316 is preferred for most coastal uses, and type 304L will corrode if exposed to de icing salt, according to the steel industry’s stainless steel handbook. Near the Shore or a salted road, use 316.
- Brass and bronze. Warm, classic and heavy. They darken and change color over time unless sealed.
Smooth finishes hold up better than rough ones near salt, since rough surfaces trap more salt, according to the same handbook. Our guide to the best outdoor sign materials covers salt and weather in more detail.
Finishes That Last
Painted letters are only as good as the paint. Architectural paint standards come in three tiers. AAMA 2603 is the basic tier, 2604 calls for 5 years of color retention and chalk resistance and 2605 calls for 10 years, based on South Florida exposure testing, according to coatings maker Tnemec. For outdoor letters, ask for 2604 or 2605.
- Brushed. Hides fingerprints and small scratches. Popular for lobbies.
- Polished. A mirror shine that needs more cleaning.
- Painted. Any brand color, with the right paint tier.
- Patina. Aged bronze or copper looks.
Mounting Methods
- Stud mount. Threaded studs on the back of each letter go into drilled holes, often with spacers to hold the letter off the wall. A paper pattern marks every hole.
- Flush mount. Letters tight to the wall with studs or adhesive.
- Standoff. Letters held off the wall to cast a shadow, or to make room for halo lighting.
- On glass or panels. Letters on a clear or metal panel with standoffs. See our standoff signs.
NYC Rules for Metal Letters
In NYC historic districts, individual dimensional letters can be no taller than 18 inches and can project up to 2 inches from the sign band, according to the Landmarks guidebook. Across NYC, a licensed sign hanger is required unless a sign is no more than 75 square feet and no more than 25 pounds, according to the Department of Buildings. A full set of metal letters can pass 25 pounds quickly, so plan for a licensed installer. Our guide to business signs in historic districts covers more.
Permits in New Jersey
Exterior metal letters usually need zoning approval and a permit in New Jersey towns. Interior lobby letters usually do not. Read do business signs need a permit in New Jersey, and let our sign permits team handle it.
Cost and Lifespan
Flat cut aluminum is usually the most affordable metal letter. Fabricated and cast letters cost more, and bronze and brass cost the most. Metal letters last a long time when the metal and finish suit the site, and Gemini offers a lifetime guarantee on its cast letters. Our sister company in New York compares sign materials in storefront sign materials.
Metal Letters and Your Brand
Match the metal and finish to the rest of your brand, from business cards to vehicles. Pixel Wraps, our sister graphics shop, makes the same case for choosing materials carefully in 3M vs Avery Dennison vehicle wrap vinyl.
Lighting Metal Letters
Fabricated and some cast letters can be halo lit, with LEDs behind the letter shining onto the wall. Halo lighting works well for lobbies and for towns that limit internal lighting. Montclair and NYC Landmarks both allow halo lit letters. Spotlights aimed at unlit letters are another option. Our guide to lit and unlit signs compares them.
Care and Cleaning
Wipe interior letters with a soft cloth. Outdoors, rinse stainless and painted letters with clean water after winter to remove salt. The stainless steel handbook says quarterly cleaning gives stainless the most attractive appearance, and recommends a more corrosion resistant grade if regular cleaning will not happen. Avoid abrasive pads that scratch brushed finishes.
Ordering Tips
- Ask for a finish sample before the full order.
- Confirm the metal grade and paint tier in writing.
- Check the wall for blocking or a solid surface for studs.
- Get a full size paper pattern to check size and spacing on the wall.
Common Questions About Metal Letters
What metal is best for outdoor letters?
Aluminum for most signs. Near the coast or salted roads, use type 316 stainless if you want stainless, since type 304L can corrode from de icing salt.
What is the difference between cast and flat cut letters?
Cast letters are poured into a mold and are solid in front. Flat cut letters are cut from flat metal sheet by laser, router or waterjet.
Will stainless letters rust near the ocean?
Type 316 is preferred near the coast. Lower grades can stain or corrode, especially with rough finishes and no washing.
How are metal letters mounted?
Usually with threaded studs into drilled holes, often with spacers. They can also mount on panels, glass or with adhesive indoors.
How big can letters be in a NYC historic district?
Individual dimensional letters can be no taller than 18 inches and project up to 2 inches, under the Landmarks rules.
Do metal letters need a licensed installer in NYC?
Yes, unless the sign is no more than 75 square feet and no more than 25 pounds. A full set of metal letters often exceeds 25 pounds.
Metal Letters Made in Linden
We help you choose the metal, finish and mounting, and we install. See our metal letters, then request a free quote.
