This is my current project I am working on for the Yoder Barn Theatre in Newport News Virginia. The sign is ten foot long, made from Dupont Corian and machined on the ShopBot at CNU. This is the first time I have made a sign longer than the ShopBot's eight foot long bed. I used a laser pointer in the Spindle chuck to reset the XY origin on a match line that I cut on the left end to cut the remaining text on the right side. I used a 60 degree router bit for the outlines and cut the waste areas with a 1/4" end mill. The 60 degree bit provides the nice sharp outlines and square corners.
The pictures demonstrate one of the reasons that Corian is such a great material for signs. The technique couldn't be any simpler, after machining or laser engraving the text you spray paint the recessed areas. You then sand the top surface with a random orbital sander which removes the surface paint leaving pristine text and graphics without the need for masking. The labor savings more than offset the cost of the material. This sign can be refreshed or the color changed every few years while it is in place by spray painting again and sanding the surface with an ROS.
This sign will be mounted on a curved exterior brick wall that has an 11" chord over 20 feet on Thursday, weather permitting. Today I will be fabricating the mounting brackets and purchasing the fasteners.
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