Flat-Cut Letters Guide
Flat-Cut Letters Guide

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

Not all vinyl signs are the same. The film grade, ink system, and laminate you choose determines whether your sign looks sharp for 3 years or 10 — and whether it peels, fades, or stays perfect through Australian sun and rain.

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

ESSENTIAL — PLASMA CUT METAL LETTERS

Who it is for:

Entry-level businesses, pop-up retail, temporary promotions, short-term campaigns.

The sign uses standard cast vinyl with solvent ink and no laminate. It goes on clean, looks great on day one, and does its job. Colours are CMYK matched. The outdoor lifespan is typically 3 to 4 years before fade starts, depending on sun, heat, and coastal humidity.

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:

Established cafes, retail stores, offices, and businesses that repaint or refit every 5-7 years.

Premium uses long-term cast vinyl with eco-solvent ink and a gloss over-laminate. The laminate adds UV protection and keeps the surface wipe-clean. Colours are Pantone-referenced so they match your brand guidelines. Wet application means cleaner install with no bubbles.

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:

Flagship stores, franchise rollouts, high-end retail, anywhere brand consistency is non-negotiable.

Elite uses premium cast vinyl with UV-cured ink, the same technology used in automotive and architectural graphics. A UV-blocking matte laminate sits on top, cutting UV degradation dramatically. Colours are spectrophotometer-verified to exact Pantone values.

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

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

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