Built Up Letters vs Flat Cut vs Acrylic: Which to Pick

If you want your name on the wall rather than on a panel, you have three realistic choices. They look different, they cost very different amounts, and only one of them lights up properly.

Built up letters

A built up letter is fabricated: a face, a returned side and a back, made as a hollow three dimensional shape. That hollow lets you put LEDs inside, which is why almost all illuminated lettering is built up. Faces can be acrylic, painted aluminium, stainless steel or brass. Expect £3,000 upwards for a shopfront set, more for premium metals.

Best for: hotels, professional firms, showrooms, anywhere the sign needs to look expensive because the product is.

Flat cut letters

A single thickness of material cut to the letter shape and mounted to the wall, usually on stand off locators so it throws a shadow. Materials are typically acrylic, aluminium, stainless steel or brass. There is no cavity, so these are not internally lit, although they can be lit externally or halo lit if mounted on a backing tray.

Best for: offices, clinics, studios and anyone who wants a smart dimensional look without the fabrication cost. Often half the price of built up.

Acrylic letters

Acrylic is a material rather than a construction method, and it is worth calling out separately because it is the value option. Cut from solid coloured or painted acrylic, typically 10mm to 25mm thick, it gives depth and a clean edge at the lowest price of the three. It can be face lit if built up, or lit from behind.

Best for: budget conscious refits, internal reception lettering and businesses wanting colour matched branding.

Lighting compared

• Face lit, the letter face glows. Needs built up construction with an acrylic face
• Halo lit, light spills out behind the letter onto the wall. Works with built up letters and with flat cut on a backing
• Externally lit, trough or spot lights aimed at the letters. Works with all three and is the cheapest
• Unlit, all three work perfectly well unlit given good contrast against the wall

Outdoor durability

Stainless steel and brass will outlast everything and are the right call on the coast or on exposed elevations. Painted aluminium is excellent and can be finished in any RAL colour. Acrylic is fine outdoors but colours in the red family fade fastest in strong sun, so a UV stable grade matters.

How to decide

Start with lighting. If the letters must glow at night, you need built up. If not, flat cut usually gives the best look per pound. If budget is tight, acrylic gets you dimension for the least money.

See samples before you commit

We manufacture all three in house, so we can show you material samples and mock ups on a photo of your building before anything is made. Call 0800 454 613 or request a call back.