Turkey Channel Letter Manufacturing Guide: Factory Workflows, CNC Automation & Quality Control
An in-depth look inside Alim Reklam's 1,400 m² Bursa manufacturing plant. Discover how CNC fiber laser cutting, automated 3D coil bending, micro-laser welding, and 24-hour electrical burn-in testing guarantee flawless illuminated channel letters for international sign markets.
The 6-Stage Industrial Fabrication Process
Stage 1: CAD/CAM Vector Engineering & Dialux LED Simulation
Every client artwork is processed through specialized nesting and letter-development software. We calculate the exact stroke depth, return notch positioning, and run Dialux LED lighting simulations to eliminate dark spots and hot spots across the acrylic face.
Stage 2: Trumpf Fiber Laser Cutting (±0.1 mm Precision)
Faces and backs are cut using industrial fiber lasers with nitrogen assist gas. This ensures dross-free, clean edges on 304 stainless steel and cast PMMA acrylic sheets, ready for immediate assembly without hand filing.
Stage 3: Automated 3D Return Flanging & Bending
Coil strips of aluminum and stainless steel are fed into multi-axis CNC bending machines. Micro-notches and curved radii are bent automatically according to vector coordinates, ensuring exact font shape repeatability.
Stage 4: Handcrafted Micro-Laser Welding
Skilled technicians weld the returns to letter faces using high-precision pulse laser welders. This produces an ultra-strong seam without heat discoloration or warping on mirror and brushed finishes.
Stage 5: Samsung IP67 LED Modules & Wiring
Letters receive Samsung 2835 SMD LED modules with wide-angle 160° optic lenses. All internal wiring uses UL-certified silicone heat-resistant cables with sealed terminal connections.
Stage 6: 24-Hour Continuous Burn-in & Water Immersion Test
Prior to packing, every sign runs continuously for 24 hours under electrical load while undergoing water spray testing to verify IP67 sealing and driver thermal stability.
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