Laser cut metal signs offer some of the highest margins in the sign industry—200-400% markup is standard for custom work. The combination of perceived value (metal = premium) and relatively low material costs makes this product line worth developing.
This guide covers the practical business side: material selection, thickness options, pricing formulas, and whether to invest in equipment or outsource production. Whether you’re adding metal signs to an existing product line or starting fresh, you’ll find the numbers you need to make decisions.
Metal materials comparison
Different metals suit different applications. Here’s how they compare for signage:
| Material | Cost/m² | Durability | Best Applications | Notes |
|---|---|---|---|---|
| Mild steel | £15-30 | Good (needs coating) | Industrial, outdoor | Rusts without powder coat |
| Stainless steel | £40-80 | Excellent | Marine, food service, premium | 304 grade standard, 316 for coastal |
| Aluminium | £25-45 | Excellent | Lightweight, all-purpose | Won’t rust, easy to cut |
| Corten steel | £35-55 | Excellent | Rustic, architectural | Develops protective rust patina |
| Copper | £80-150 | Good | Decorative, high-end | Develops green patina over time |
| Brass | £90-160 | Good | Premium indoor, traditional | Tarnishes without lacquer |
For most sign shops: Mild steel (powder coated) handles 60-70% of orders. Aluminium covers lightweight and marine applications. Stainless and copper serve premium markets.
Thickness and gauge guide
Metal thickness affects both appearance and structural integrity. Common gauges for signage:
| Gauge | Thickness (mm) | Weight (steel/m²) | Use Case |
|---|---|---|---|
| 18ga | 1.2mm | 9.5 kg | Small indoor signs, decorative |
| 16ga | 1.5mm | 12 kg | Standard indoor/outdoor signs |
| 14ga | 1.9mm | 15 kg | Large signs, high wind areas |
| 12ga | 2.6mm | 21 kg | Industrial, structural |
| 10ga | 3.4mm | 27 kg | Heavy-duty, freestanding |
Rule of thumb: 16ga (1.5mm) works for most wall-mounted signs up to 600mm. Go thicker for larger signs or exposed outdoor locations.
Design limitations by thickness
Laser cutting has minimum detail constraints based on material thickness:
- Minimum hole diameter: 1× material thickness (1.5mm hole in 1.5mm steel)
- Minimum slot width: 1.5× material thickness
- Minimum letter stroke: 2× material thickness for structural integrity
- Recommended text height: 15× material thickness minimum
For 1.5mm steel, that means letters should be at least 22mm tall to maintain readability and structural strength.
Finish options
Powder coating
The industry standard for outdoor metal signs. Electrostatically applied dry powder cured at 180-200°C creates a durable, UV-resistant finish.
Advantages:
- Extremely durable (10+ years outdoor)
- Wide RAL colour range
- Even coverage including edges
- No VOCs or solvents
Cost: £15-30 per sign for standard colours, £25-45 for metallics/textures
Lead time: Adds 1-2 days to production
Raw/natural finishes
Clear lacquered steel: Shows natural metal colour with protection. Requires recoating every 2-3 years outdoors.
Brushed stainless: Directional grain pattern, no coating needed. Premium look for indoor/covered applications.
Patina finishes: Corten develops rust naturally over 6-12 months. Copper and brass can be chemically aged for immediate effect.
Paint finishes
Automotive-grade paint offers more colour options than powder coat but less durability. Reserve for indoor or covered outdoor applications.
Pricing laser cut metal signs
Material cost calculation
Base your material cost on sheet utilisation:
Sheet area needed = (sign area × 1.3) for waste factorMaterial cost = sheet area × cost per m²Example: 300mm × 450mm sign in 1.5mm mild steel
- Sign area: 0.135 m²
- With waste factor: 0.175 m²
- Steel cost: 0.175 × £25 = £4.40
- Plus powder coat: £20
- Total material: £24.40
Labour cost calculation
Typical production times:
- Simple text sign: 15-30 minutes cutting + finishing
- Complex logo: 30-60 minutes
- Setup/file prep: 10-15 minutes per design
At £40/hour shop rate, a standard sign runs £15-35 in labour.
Retail pricing formula
| Sign Size | Material | Labour | Total Cost | Retail Price | Margin |
|---|---|---|---|---|---|
| 200×300mm | £15 | £20 | £35 | £95-120 | 63-71% |
| 300×450mm | £25 | £25 | £50 | £150-200 | 67-75% |
| 450×600mm | £40 | £35 | £75 | £225-300 | 67-75% |
| 600×900mm | £65 | £45 | £110 | £350-450 | 69-76% |
Add premiums for:
- Stainless steel: +50-80%
- Copper/brass: +100-150%
- Rush orders: +25-50%
- Custom colours: +10-20%
Equipment: in-house vs outsourcing
Laser cutting equipment
Entry-level fibre lasers (1-2kW): £15,000-40,000
- Cut capacity: Up to 6mm mild steel, 3mm stainless
- Suitable for: Sign shops doing 20+ metal signs/month
- Brands: OMTech, Thunder Laser, Ten-High
Professional fibre lasers (3-6kW): £60,000-150,000
- Cut capacity: Up to 20mm mild steel, 10mm stainless
- Suitable for: Dedicated metal fabricators
- Brands: Trotec, Trumpf, Bystronic, Bodor
Additional requirements:
- Extraction system: £2,000-8,000
- Compressed air: £500-2,000
- Floor space: Minimum 4m × 3m
- 3-phase power for larger machines
Outsourcing production
For shops not ready for equipment investment:
Trade laser cutting services offer:
- Cut-only pricing: £20-60 per sign (depending on complexity)
- Cut + powder coat: £40-100 per sign
- 2-5 day turnaround typically
- No minimum orders from many suppliers
Break-even calculation: At £40 average outsourcing cost, in-house makes sense at:
- Entry laser (£25k): 625+ signs to recover capital
- At 30 signs/month: 21 months payback
Many sign shops start with outsourcing, build the customer base, then invest in equipment once volume justifies it.
Selling metal signs with Sign Customiser
Sign Customiser lets customers configure and price metal signs themselves. Here’s how to set it up:
Configuration steps
1. Define material options
- Mild steel (powder coated) - standard option
- Stainless steel - premium tier
- Aluminium - lightweight option
- Corten - rustic/architectural
2. Set size tiers
- Small: up to 300mm
- Medium: 300-600mm
- Large: 600-900mm
- Extra large: 900mm+
3. Configure pricing rules
- Base price per size tier
- Material multipliers (stainless = 1.6×, corten = 1.4×)
- Colour premiums for metallic powder coats
- Rush order options
4. Add finish selections
- Standard powder coat colours
- Premium metallic finishes
- Raw/natural options
- Custom RAL matching (+£)
Benefits for your business
- Eliminates quote requests: Customers see instant pricing
- Captures specifications: Order details ready for production
- Upsells automatically: Premium options displayed during configuration
- Reduces errors: Customers confirm design before ordering
Installation methods
Wall mounting
Stud mounts: Threaded studs welded to sign back, drill holes in wall, signs project 20-50mm. Most common for business signage.
French cleats: Interlocking metal strips allow easy hanging and levelling. Good for large, heavy signs.
Direct fixing: Screws through sign face into wall. Visible fixings, but most secure method.
Adhesive: Industrial VHB tape for lightweight signs on smooth surfaces only.
Freestanding options
Post mounting: Signs welded or bolted to steel posts, set in concrete footings.
Base plates: Weighted or bolted base for indoor freestanding signs.
A-frames: Hinged construction for temporary/moveable signage.
Weight considerations
Calculate mounting requirements based on sign weight:
| Material | 300×450mm (16ga) | 600×900mm (14ga) |
|---|---|---|
| Mild steel | 1.6 kg | 5.7 kg |
| Stainless | 1.7 kg | 6.0 kg |
| Aluminium | 0.6 kg | 2.1 kg |
Use fixings rated for 3× sign weight to account for wind loading on outdoor installations.
Wholesale and trade sourcing
UK trade suppliers
For sign shops outsourcing production:
Laser cutting only:
- Online instant-quote portals
- 2-3 day turnaround typical
- Upload DXF/DWG files for pricing
Cut + finish:
- Full-service trade suppliers
- 5-7 day turnaround
- White-label delivery available
Evaluating suppliers
Check these factors:
- Cut quality: Request samples—check edge finish and accuracy
- Material sourcing: Certified steel grades, consistent quality
- Powder coating: In-house vs outsourced (affects lead time)
- Minimum orders: Some require £50-100 minimum
- Packaging: Proper protection prevents transit damage
Import considerations
Chinese suppliers offer 30-50% cost savings but consider:
- 4-8 week shipping times
- Import duties and VAT
- Quality consistency challenges
- Communication barriers
- No returns/warranty support
For most UK sign shops, domestic trade suppliers offer better value when factoring in speed and reliability.
Design best practices
File preparation
Supply files as:
- DXF or DWG: Industry standard for laser cutting
- AI or EPS: Vector formats from design software
- PDF: Acceptable if vector-based
Critical checks:
- All text converted to outlines/paths
- No open paths (closed shapes only)
- Minimum detail sizes respected
- Correct scale specified
Common design mistakes
Too thin strokes: Letters or details under 2mm will distort or break. Scale up or simplify.
Trapped shapes: Internal cuts (like the centre of “O”) need tabs or bridges, or fall out.
Ignoring kerf: Laser removes ~0.2mm of material. For precise fits, offset paths by half kerf width.
Missing mounting consideration: Design mounting holes/slots into the sign from the start.
Frequently asked questions
How much do custom laser cut metal signs cost?
Material and complexity drive pricing. Simple powder-coated steel signs: £95-150 for 300×450mm size. Stainless steel adds 50-80%. Large format (600×900mm+) runs £250-450. Rush orders add 25-50%.
How long does production take?
Standard turnaround: 5-10 working days including powder coating. Rush orders: 2-3 days at premium. Cut-only (no finishing): 2-3 days.
What file format do I need?
Vector files: DXF, DWG, AI, or EPS. All text must be converted to outlines. Avoid JPG/PNG—these are pixel-based and can’t be cut accurately.
Can any design be laser cut?
Most designs work with modifications. Limitations: minimum 2mm detail width, closed shapes required, internal cuts need bridges. Simple logos and text cut cleanly. Photographic images need conversion to suitable line art.
How do laser cut signs compare to vinyl or printed signs?
Laser cut metal costs more upfront but lasts 10-20× longer outdoors. Perceived value is significantly higher—customers pay premium prices. Break-even vs vinyl: typically 3-5 years for outdoor signage.
Do metal signs rust?
Untreated mild steel rusts quickly. Powder coating prevents rust for 10+ years. Stainless steel and aluminium don’t rust. Corten steel develops controlled rust as a design feature.
