Custom pan formed sign faces give sign companies a durable, dimensional option for projects that need more visual impact than a flat face. World Wide Sign Systems, Inc. manufactures each face to the approved artwork and project specifications, with options for decorated or non-decorated faces, embossed or debossed details, custom shapes, and both small and large quantities.
For sign professionals, the value is flexibility. One manufacturing process can support replacement faces, new sign cabinets, distinctive brand shapes, illuminated applications, and large-format projects. WWSS can form faces up to 8 feet by 20 feet in one seamless piece, while flat faces and digitally printed flex faces are also available when a different construction is a better fit.
What is a pan formed sign face?
A pan formed sign face—also called a formed face, molded face, or vacuum formed plastic face—is made by heating plastic and shaping it over a custom mold. The result is a rigid, three-dimensional face that can include raised or recessed copy, logos, borders, and other design elements.
Compared with a flat face, the added depth helps lettering and graphics catch light during the day. In an internally illuminated cabinet, the dimensional surface can also create a strong nighttime presentation. Formed faces are commonly produced in UV-stabilized polycarbonate or acrylic, depending on the specifications of the project.
How does a formed face go from artwork to a finished sign?
Every project begins with the artwork and the requirements supplied by the sign company. The WWSS sales and manufacturing teams review the size, shape, depth, material, decoration, illumination, and installation needs before production begins.
- Artwork and specifications are reviewed. The approved design establishes the shape, copy, logo details, colors, and finished dimensions.
- A precision mold is prepared. The mold creates the raised, recessed, or contoured areas that give the face its dimensional appearance.
- The plastic sheet is heated and formed. Once the material reaches the correct forming temperature, it is drawn over the mold to reproduce the design.
- The face is trimmed and prepared. The formed piece is finished to the required size and configuration so it can fit the intended sign cabinet or application.
- Decoration is applied when requested. Depending on the project, WWSS can use second-surface paint, first- or second-surface translucent vinyl, pre-applied vinyl, or digitally printed graphics.
- The finished face is inspected and prepared for shipment. The team checks the surface, color, fit, and overall finish before the face is packed for delivery.
Which formed face options are available?
Pan formed faces can be tailored to the needs of a single replacement project or a larger sign program. Available options include:
- Decorated or non-decorated faces
- Embossed or debossed lettering and graphics
- Custom shapes and odd sizes
- Clear, white, or project-specific material options
- Small quantities and high-volume production
- Single-piece formed faces up to 8 feet by 20 feet
- Flat sign faces
- Flexible faces with digital print or vinyl decoration
The right choice depends on the cabinet, viewing distance, illumination, artwork, environmental exposure, and desired finished appearance. The WWSS sales team can help determine which construction and decoration method best fits the job.
Why do sign companies choose WWSS for formed faces?
World Wide Sign Systems has manufactured wholesale custom signs since 1958. Customers work with an experienced sales department, receive quote turnaround typically within 24 to 48 hours, and have access to manufacturing support from facilities in Bonduel and Shawano, Wisconsin; Atlanta, Georgia; and Carson City, Nevada.
Those U.S. locations help WWSS serve sign companies across the country while supporting projects ranging from one custom replacement face to larger quantities. No project is too big or too small.
Frequently asked questions about pan formed faces
How large can a formed sign face be?
WWSS can manufacture a formed face up to 8 feet by 20 feet in one seamless piece. Larger applications may be produced as matched panel sets when appropriate.
Can WWSS make a replacement face for an existing sign cabinet?
Yes. Replacement formed faces can be manufactured for existing cabinets when accurate measurements, retainers, depth requirements, and other project details are provided.
Do all formed faces need to be decorated?
No. Sign companies may order decorated or non-decorated faces. Decoration options include paint, translucent vinyl, pre-applied vinyl, and digitally printed graphics.
Are formed faces only available in standard rectangles?
No. Custom shapes, odd sizes, embossed designs, and debossed details are available based on the approved artwork and manufacturing requirements.
Request a quote for a custom formed face
Need help deciding whether a custom pan formed face is right for your next sign project? Review WWSS’s formed face sign manufacturing capabilities, then request a quote or contact the wholesale sign manufacturing team.
Call 1-800-874-3334 or email sales@wwsign.com.