How Sandblasted Signs are made

We begin with 4' x 8' sheets of high density urethane foam board. This material was developed specifically for use in the sign industry as a replacement for wood. It is impervious to any sort of natural decay, and completely stable regardless of weather conditions. This results in longer lasting finished signs. "Blanks" are cut to size using standard woodworking tools.

Signs are then designed using a graphics application on a PC. The computer enables including graphic elements from a wide range of sources. After the various parts of the sign are manipulated to produce a pleasing overall composition, the completed "layout" is output to a plotter.

The plotter draws the sign, full scale, on thin self-adhesive vinyl. After the "blank" is covered with a special rubber-like sandblast mask, the "layout" is applied over the mask. Next, with the layout as guide, the mask is cut away from areas to be sandblasted, primarily with routers.

Next comes sandblasting. We do this in a special enclosure which enables recycling of the low-dust abrasive. This process is somewhat complicated with the HDU material, involving several steps. A random dramatic wood grain pattern is created using a frame with hundreds of steel wires.

After sandblasting, the mask is removed and discarded; edges are finished with various router bits. Each sign is then completely sealed with a special primer, designed expressly for the HDU material. Next, it is painted with top-quality exterior paints & stains. Last, but by no means least, the sign is turned over to a skilled artist for detail work with fine brushes and acylic paints.

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