Flat-Cut Letters Guide
Flat-Cut Letters Guide

METAL FLAT-CUT LETTER QUALITY GUIDE — PLASMA CUT VS WATERJET VS EDGE POLISH

The cut method determines edge smoothness. The finish determines how the sign looks in 5 years. Material quality speaks loudest on non-illuminated signage.

Premium vinyl shopfront sign installed on glass vibrant clean edges Perth - Neon Brothers
ESSENTIAL
ESSENTIAL

ESSENTIAL — PLASMA CUT METAL LETTERS

Who it is for: Who it's for: Budget office exterior, small business, short-term.

2mm aluminium, plasma cut — rough edge visible close-up and in raking light. 1-coat spray enamel. Adhesive foam tape. Non-illuminated.

Spec at a glance
2mm aluminium · Plasma cut · 1-coat enamel · Adhesive tape · Non-illuminated
Essential tier vinyl sign example - Neon Brothers
PREMIUM
PREMIUM

PREMIUM — WATERJET CUT METAL LETTERS

Who it is for: Who it's for: Corporate, retail facades, restaurants, permanent commercial.

3mm aluminium, CNC waterjet — clean, precise, smooth edge. Powder coat 15yr outdoor rated. SS304 threaded stud. Non-illuminated.

Spec at a glance
3mm aluminium · CNC waterjet · Powder coat 15yr · SS304 stud · Non-illuminated
Premium tier vinyl sign example - Neon Brothers
ELITE
ELITE

ELITE — CHAMFERED & POLISHED METAL LETTERS

Who it is for: Who it's for: Architectural, premium office, high-end retail.

3mm SS304 or 5mm aluminium. Waterjet + 45° chamfer + edge polish — jewellery-like edge quality. Anodised / brushed / UV lacquer. SS316 concealed stud + template. Edge-lit LED option available.

Spec at a glance
3mm SS304 or 5mm alu · Waterjet + 45° chamfer + polish · Anodised/brushed/UV · SS316 + template · Edge-lit option
Elite tier vinyl sign example - Neon Brothers
Side by Side
Side by Side

PLASMA VS WATERJET VS CHAMFER + POLISH

Spec Essential Premium ★ Elite
Film 2mm aluminium 3mm aluminium 3mm SS304 or 5mm aluminium
Cut Method Plasma — rough edge CNC waterjet — clean Waterjet + 45° chamfer + polish
Finish 1-coat spray enamel Powder coat 15yr outdoor Anodised / brushed / UV lacquer
Mounting Adhesive tape SS304 stud SS316 concealed + template
Lighting None None Edge-lit LED option
Warranty 1 year 2-year NBCare™ 2-year NBCare™
Three vinyl signs comparison showing quality differences over time - Neon Brothers
FAQ
FAQ

METAL FLAT-CUT LETTERS — FAQ

Plasma vs waterjet cut?+
Plasma: rough, oxidised edge. Waterjet: perfectly clean, smooth, no heat distortion. Visible difference side-by-side.
What is a 45° chamfer?+
Precision bevel on top edge, then polished. Catches light. Jewellery-like quality impossible with plasma or basic waterjet.
Spray enamel vs powder coat?+
Enamel: basic, thin. Powder coat: electrostatically baked, 15+ year outdoor rating. Far more durable.
Can flat-cut letters be illuminated?+
Essential/Premium: no. Elite: edge-lit LED option — LED strip behind creates a subtle glow without a lightbox.
Aluminium or stainless steel?+
Aluminium: lighter, powder coat. SS304: brushed natural metal finishes. SS316: coastal locations within 5km of ocean.
What thickness?+
2mm: thin. 3mm: standard, more shadow. 5mm: maximum depth — architectural large-format.
Do you ship signs Australia-wide?+
Yes. All signs are custom made and shipped tracked to any address in Australia — Perth, Sydney, Melbourne, Brisbane, Adelaide, and regional areas. Signs are packed flat with protective backing to prevent damage during transit.
What finishes?+
Essential: spray enamel. Premium: powder coat RAL. Elite: anodised, brushed SS, UV lacquer.
BROTHERS

NEED COASTAL GRADE SS LETTERS? TELL US YOUR SUBURB

Tell us the text, letter height, material, and suburb — we recommend the right cut method, finish, and mounting.

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