This is a specific and high-quality construction method, often referred to as “Deep-Pour Resin Face” or “Epoxy-Filled” channel letters.
Breakdown of the Components You Mentioned:
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SS/Aluminum Weld to 20-100mm Deep: This is the can or tray of the letter.
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Material: Stainless Steel (SS) for extreme durability and a premium finish, or Aluminum for a excellent balance of cost, weight, and weather resistance.
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Depth (20-100mm): This is a key feature. A depth of 20mm (0.78″) is standard, but going to 40mm, 60mm, or even 100mm (almost 4″) creates a dramatic, deep, and luxurious 3D effect. This deep can is what holds the large volume of resin.
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Opal Acrylic on the Front: This is the face of the letter.
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Opal Acrylic: This is a milky white, semi-translucent plastic. It acts as a diffuser, spreading the light from the internal LEDs evenly across the entire face of the letter, eliminating hot spots and creating a smooth, consistent glow.
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Resin Cover the Surface of the Front: This is the defining characteristic.
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A liquid epoxy or polyurethane resin is carefully poured into the deep can, on top of the opal acrylic face.
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It cures to form a hard, crystal-clear, domed lens over the entire front of the letter.
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Internally Illuminated: The light source.
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Modern LED modules are placed inside the deep can, along the interior walls. Their light shines inward, reflects off the painted-white interior, and passes through the opal acrylic and then the resin dome.
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The Resin Makes the Lights Much More Beautiful: This is the primary benefit.
Why Resin is Used: The “Beautiful” Effects
The resin transform a standard lit letter into something special:
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Crystal-Clear, Glass-Like Finish: The resin creates an incredibly smooth, glossy, and professional surface that is far superior to plain acrylic. It feels premium and high-end.
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Depth and Dimension: The deep pour of resin acts like a magnifying lens, making the illuminated face appear to “float” within the depth of the letter. This creates incredible depth and a striking 3D effect, especially during the day.
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Vivid and Uniform Illumination: The resin helps to further diffuse the light, eliminating any potential faint shadows from the LED modules and creating a perfectly even, vibrant glow across the entire letterform.
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Durability and Protection: The cured resin is very hard and impact-resistant. It protects the opal acrylic face from scratches, UV yellowing, graffiti, and harsh weather conditions, ensuring the sign looks new for years.
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Easy Cleaning: The non-porous, smooth surface makes it very easy to clean dirt and grime off the sign.
Typical Fabrication Process:
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Design & Template: The letter shapes are designed and laid out for fabrication.
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Can Fabrication: The sides (returns) of the letters are bent from stainless steel or aluminum sheet to the specified depth (e.g., 60mm). The seams are welded and ground smooth for a seamless look.
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Face Cutting: The opal acrylic faces are precisely cut using a CNC router or laser cutter.
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Painting & Wiring: The inside of the metal can is painted high-gloss white to maximize light reflection. LED modules are spaced and wired along the inside perimeter of the can.
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Assembly: The opal acrylic face is solvent-welded to the metal can, creating a water-tight vessel.
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Resin Pouring: This is the critical step. The letter is placed perfectly level. The two-part resin is mixed, often degassed to remove air bubbles, and then slowly poured into the can. It self-levels to create a perfectly smooth, domed surface.
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Curing: The resin is left to cure for 24-48 hours in a dust-free environment.
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Installation: The finished letters are mounted to a raceway or directly to the building facade using studs.
Ideal Applications:
This type of signage is used where a premium, high-impact brand image is desired:
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Corporate headquarters and high-rise buildings
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Luxury retail stores (jewelry, fashion, automotive)
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Hotels and high-end restaurants
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Shopping malls and flagship stores
In summary, you have described the process for creating deep-pour, resin-filled, front-lit channel letters. They are one of the most attractive and durable types of illuminated signage available, renowned for their deep, luxurious glow and crystal-clear appearance.
