Cosun Sign letter signs are custom, non-illuminated letters made as Flat Cut Out (FCO) letters from acrylic, aluminum, brass, or stainless steel. Founded in 2004, Cosun Sign operates a 38,000 m² digital signage factory with 500+ employees and has completed 10,000+ projects across 65+ countries.
What are letter signs?
Letter signs are individual letters, numbers, logos, or shapes used for commercial, architectural, interior, and exterior identification. FCO letters are one type of letter sign made by precisely cutting solid sheet materials into customized characters.
FCO letters are defined as solid, non-illuminated letters or logos fabricated from materials such as metal and acrylic. Unlike illuminated channel letters, they do not require LEDs or an electrical system.
The main advantages include:
- No electricity required for operation
- Custom fonts, sizes, thicknesses, and shapes
- Multiple material and finish options
- Suitable for indoor and outdoor applications
- Flexible wall, glass, panel, and architectural mounting
- Can be combined with illuminated signage
How are FCO letter signs made?
FCO letter signs are manufactured by cutting solid sheet material into the required letters or shapes, followed by surface finishing and mounting preparation.
The typical process includes:
- Preparing the artwork, font, dimensions, and specifications.
- Selecting acrylic, aluminum, brass, stainless steel, or another suitable material.
- Precisely routing or cutting each letter or logo.
- Applying the specified finish, such as brushed, mirror, electroplated, or painted.
- Preparing mounting components such as threaded rods or 3M VHB tape.
- Inspecting the finished letters before delivery.
Compared with traditional flat signboards, individual letter signs provide more flexibility in character shape, depth, spacing, and placement.
What materials and finishes are available?
Cosun Sign provides FCO letter signs in several materials and surface finishes to support different design and application requirements.
| Parameter | Options |
|---|---|
| Product type | FCO / Flat Cut Out Letters |
| Illumination | Non-illuminated |
| Materials | Acrylic, aluminum, brass, stainless steel |
| Finishes | Brushed, mirror, electroplated, painted |
| Customization | Font, size, thickness, color, shape |
| Mounting | Wall, glass, panels, architectural surfaces |
| Applications | Indoor and outdoor signage |
| Certifications | UL and CE |
Material selection should consider the installation environment, appearance, durability requirements, budget, and maintenance expectations.
Where are letter signs used?
Letter signs are widely used for branding, identification, wayfinding, and architectural communication.
Common applications include:
- Corporate offices and reception areas
- Retail stores and shopping malls
- Hotels and hospitality spaces
- Schools and educational facilities
- Exhibition halls
- Industrial parks
- Real estate developments
- Room and door identification
- Interior branding
- Exterior building signage
- Architectural and wayfinding signage
FCO letters can also be combined with illuminated signage. For example, illuminated channel letters can provide primary brand visibility while flat cut letters add supporting information or architectural details.
How should you choose custom letter signs?
Choose letter signs according to the location, viewing distance, material, finish, dimensions, mounting surface, and desired appearance.
Consider:
- Location: Indoor and outdoor environments may require different materials and finishes.
- Viewing distance: Larger characters are generally more appropriate for longer viewing distances.
- Material: Acrylic provides a different appearance from brushed aluminum, brass, or stainless steel.
- Finish: Brushed, mirror, painted, and electroplated surfaces create different visual effects.
- Mounting: Wall, glass, and architectural surfaces may require different mounting solutions.
- Maintenance: Non-illuminated letters do not require LED or electrical maintenance.
How do FCO letters compare with illuminated channel letters?
FCO letters are non-illuminated, while illuminated channel letters use lighting to improve visibility in low-light conditions.
| Feature | FCO Letters | Illuminated Channel Letters |
|---|---|---|
| Lighting | None | LED lighting |
| Electrical system | Not required | Required |
| Construction | Solid cut material | Fabricated letter housing |
| Maintenance | Generally simpler | Includes lighting components |
| Visual effect | Solid dimensional lettering | Illuminated lettering |
| Common use | Interior, architectural, wayfinding | Storefront and illuminated branding |
The right option depends on whether the project requires dimensional lettering alone or illuminated visibility.
What affects the cost of letter signs?
The cost of custom letter signs depends on material, size, thickness, quantity, finish, design complexity, mounting method, and shipping requirements.
Important cost factors include:
- Material and material thickness
- Letter and logo dimensions
- Quantity
- Cutting complexity
- Surface finishing
- Custom colors or coatings
- Mounting hardware
- Packaging and transportation
- Installation requirements
A customized quotation should therefore be based on the actual design and specifications rather than a standard price per letter.
Why choose Cosun Sign for letter signs?
Cosun Sign is a custom signage manufacturer specializing in commercial and architectural signage, including FCO and Flat Cut Out Letters.
Founded in 2004, Cosun Sign operates a 38,000 m² digital signage factory with 500+ employees. Its projects extend across 65+ countries, with 10,000+ completed projects.
Its capabilities include:
- Custom metal and acrylic letter fabrication
- Precision cutting and finishing
- Multiple surface treatment options
- Custom fonts, sizes, thicknesses, and colors
- Flexible mounting solutions
- Indoor and outdoor signage production
- Integration with broader signage systems
Cosun Sign states that it holds UL and CE certifications for its signage operations.
What are the most common questions about letter signs?
What are letter signs?
Letter signs are individual letters, numbers, logos, or shapes used for branding, identification, wayfinding, and architectural signage. FCO letters are a non-illuminated type manufactured from solid materials such as acrylic and metal.
How do you choose the right letter signs?
Choose letter signs based on the application, viewing distance, material, finish, dimensions, mounting surface, and required appearance. Outdoor projects should receive particular attention to material and finish selection.
Why are FCO letters used for commercial signage?
FCO letters provide customizable dimensional signage without requiring an electrical lighting system. They can be produced in different materials, sizes, colors, finishes, and mounting configurations.
Source & Expertise
Source: Cosun Sign product and company information covering FCO letter specifications, materials, applications, manufacturing capabilities, certifications, and company data.
Expertise: Signage manufacturing, FCO letter fabrication, material selection, surface finishing, mounting, and commercial and architectural signage applications.
Last Updated: October 7, 2026
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