How we manufacture flex face letters and flex face shapes with SignComp Econoflex

Mention flex face signage and most people picture a large rectangular box. But a rectangle is far from the only option.

Using the SignComp Econoflex system, the same flex face principle can be applied to individual letterforms, logos and other non-standard shapes. At Brownings, we manufacture these flex face letters and flex face shapes for trade sign makers, forming the extrusion around the required outline rather than restricting the job to a conventional square or rectangular box.

The result is a useful additional option when the design calls for the scale and appearance of flex face signage but needs to follow a brand shape, letter or logo.

What are flex face letters?

A conventional flex face sign uses a flexible graphic face tensioned across a frame. With flex face letters, that principle remains the same, but the perimeter of the sign follows the shape of the individual letter rather than a rectangle.

That sounds straightforward. Manufacturing it is less so.

Every curve, internal corner and change of direction has to work with the extrusion system while still allowing the flex face to be correctly tensioned around the finished shape.

This is where practical experience with the system matters.

Taking Econoflex beyond the rectangular box

SignComp Econoflex is well known as a flex face box system, particularly for illuminated signage. Its extrusion can also be manipulated to create shaped work, including letters and logos.

Producing Econoflex letters starts with the same fundamental system, but the geometry of the job changes the manufacturing process considerably.

Instead of cutting straight lengths for four sides of a box, the extrusion has to follow the outline of the artwork. Controlled cuts allow the profile to be formed around curves and changes of direction while retaining the parts of the system needed to assemble and tension the finished flex face.

The more involved the outline becomes, the more important those manufacturing decisions become.

What the workshop photograph shows

The photograph above is a good example.

Rather than a standard rectangular flex face box, the frame follows a substantial curved outline with both inner and outer radii. The tension clips can be seen following the perimeter of the shape.

That detail matters. The finished graphic still needs to be tensioned securely around the complete face, so manufacturing the frame is not simply a matter of achieving the right outline. The profile, corners and tensioning route all have to work together.

For a sign maker, that means the original artwork needs to be considered as a physical sign system rather than simply a two-dimensional drawing.

Not every logo automatically makes a good flex face shape

This is an important point when specifying flex face shapes.

Something that works perfectly on screen may need some consideration before it can be manufactured as an Econoflex letter or logo.

Areas worth checking include:

• very tight curves or radii;
• acute internal angles;
• narrow sections of a letter or logo;
• areas where separate elements sit very close together;
• whether there is sufficient space to form and tension the flex face;
• illumination requirements where the sign is to be internally lit.

None of these automatically rules out a design. They are simply the practical details worth considering before the job reaches production.

Getting Brownings involved while the artwork and specification are still being developed can therefore help establish whether Econoflex is the right route for the design.

Why specify flex face letters?

For the right project, flex face letters allow a sign maker to take the established flex face principle and apply it to a much more distinctive outline.

Rather than placing the complete identity within one large rectangular light box, individual letters or logo elements can become the flex face sign themselves.

This can be useful for schemes where the shape of the identity is an important part of the finished appearance, particularly when a standard rectangular box would introduce a background or outline that the designer does not want.

It also gives sign makers another option when considering larger letterforms and shaped illuminated signage.

The important point is that the solution still needs to be specified around the design. Profile choice, shape, face tensioning, support and illumination where required all need to work as one system.

Flex face shapes require manufacturing knowledge

Shaped work is a good example of why Brownings specialises in extrusion-built signage systems.

Producing a rectangle accurately is one skill. Taking that extrusion system around a series of curves, internal corners and letterforms while retaining a workable flex face tensioning system introduces another level of manufacturing consideration.

That is the knowledge behind the Econoflex letters and shaped units we manufacture for the trade.

Brownings is a trade-only sign manufacturer, so our role is to support the sign maker supplying the finished project rather than competing for their end-user work.

Planning a shaped Econoflex project?

If you are considering flex face letters, a shaped logo or another non-rectangular flex face sign, it is worth discussing the artwork before the specification is finalised.

Send Brownings the proposed design together with the relevant size, finish, illumination and supply requirements, and we can discuss the application and whether the selected flex face system is appropriate for the job.

For supporting videos on skin preparation and tension clips, see our flex face sign guides and resources.

Built for the trade. The Sign Makers’ Sign Maker.

Flex face letters: frequently asked questions

Can flex face signs be manufactured as individual letters?

Yes, where the chosen system and the geometry of the artwork permit. SignComp Econoflex can be formed into letter and logo shapes rather than being restricted to rectangular flex face boxes.

Can Econoflex be used for shaped logos?

Yes. Letters, logo elements and other shaped flex face signs are possible, although the practical geometry of each design needs to be considered before manufacture.

Can any letter or logo be manufactured in Econoflex?

Not necessarily. Tight curves, acute internal angles, narrow sections and closely spaced elements can all affect manufacturability and tensioning. It is better to review the artwork before assuming a particular design will translate directly into a flex face shape.

Are Econoflex letters illuminated?

Econoflex is commonly used for illuminated flex face signage, but the illumination requirement and specification should be confirmed for the individual project.

Who does Brownings manufacture flex face letters for?

Brownings manufactures flex face signage for trade customers, principally sign makers. We support our trade customers without positioning ourselves as a competitor for their end-user work.