A

DISSERTATION
ON
“FABRICATION OF ACRYLIC 3DLETTERING

WITH ILLUMINATION”
In The Partial Fulfillment of Diploma EngineeringSubmitted
By

Barun Kumar Singh (D202101956)

UNDER THE SUPER-VISION OF

Mr. Sanjoy Banerjee
Lecturer, BCP

BENGAL COLLEGE OF POLYTECHNIC, DURGAPUR

Sahid Sukumar Banerjee Sarani, Bidhannagar, Durgapur-713212
West Bengal
 BENGAL COLLEGE OF POLYTECHNIC
Approved by AICTE, New Delhi and affiliated to WBSCT&VE&SD,Kolkata

CERTIFICATE OF ACCEPTANCE OF EVALUATION

COMMITTEE
The dissertation entitled “ Fabrication of Acrylic 3D Lettering With Illumination ” has been prepared
and submitted by Barun Kumar Singh from department of Electrical Engineering in partial
fulfillment of the requirement for the award of degree of diploma in electrical engineering at BENGAL
COLLEGE OF POLYTECHNIC, Durgapur and is here by accepted for the award of degree.

Name and Designation Evaluation Signature

MR. MANISH KUMAR Satisfactory/Not satisfactory

Principal In-charge
BCP, Durgapur

MR. PRONOY DAS CHOUDHURY Satisfactory/Not satisfactory

H.O.D
Dept. of Electrical Engineering
BCP, Durgapur

MR. ABHIJIT GHOSH Satisfactory/Not satisfactory

Project Co-ordinator
Dept. of Electrical Engineering
BCP, Durgapur

MR. SANJOY BANERJEE Satisfactory/Not satisfactory

Lecturer
Dept. of Electrical Engineering
BCP, Durgapur

The dissertation has been examined by the evaluation committee and found acceptable.
 BENGAL COLLEGE OF POLYTECHNIC
Approved by AICTE, New Delhi and affiliated to WBSCT&VE&SD,Kolkata

SELF ATTESTED
This is to certify that we have ourselves worked on the dissertation untitled “Fabrication of Acrylic
3D Lettering With Illumination”. This result mentioned in the reports has been generated during
the work and analyses are genuine. It is the result of extensive work carried out by us. The data and
information obtained from other agencies has been dully acknowledged. The report and result
submitted forward of the Diploma and Electrical Engineering is a research is a work carried out by us.
The dissertation has not been submitted for the award of diploma in any other university.

Date: Participate candidate

Place- Durgapur (Barun Kumar Singh)

 ABSTRACT

Durability is what makes the Acrylic Sign Board the best option in signage today. They
are waterproof and weatherproof, made of high-quality cast acrylic, with a classy finish.
Acrylic Signs are manufactured in variations of transparent, opaque and router-cut.
Acrylic material allows light to permeate and hence is used innovatively in signage for
light effects like smudge, smooth and clear. Sector of consumption – Corporate. Acrylic
Letter Sign Boards are presentation boards designed with multi range of colours and size.
Acrylic letters help to suit your organization’s branding and marketing needs. As these
boards are Portable display boards, can modified with header panels, designed panels
sheets, posters. All letter sign boards packed with sealed box included and are prepared
at Designer Site. Prices from acrylic letter board manufacturing depend upon size and
colour of material of letter boards.
 ACKNOWLEDGEMENT

We deem it a privilege to have been the student of BENGAL COLLEGE OF

POLYTECHNIC, DURGAPUR Department of Electricall Engineering. We are grateful to
our advisor MR. SANJOY BANERJEE, Lecturer, department of ELECTRICAL
ENGINEERING, for introducing us to this topic, his kind support, guidance, and
encouragement throughout the dissertation work.

We would also take this opportunity to express our gratitude and sincere thanks to
our Principal in Charge MR. MANISH KUMAR, Bengal College Of Polytechnic
and MR. PRONOY DAS CHOUDHURY, HOD Of Electrical Engineering Department for
hisinvaluable advice, encouragement, aspiration and blessing.

We would like to take chance to express our appreciation to our family member for
constant prayer support and inspirational encouragements and moral supports which enables
us to pursue our studies. Their continuous love and support gave us strength to pursuing our
dream. Special thanks to our friend and other members of the department for being so
supportive and helpful in every possible way. We are very thankful to our entire faculty and
staff members of Electrical Engineering, Bengal College of polytechnic, and Durgapur
for their direct and indirect help and co-operation.

Best Regards to All of You!

Student Signature
 INDEX
Sr.No Title Page No

Introduction 01
1.  Overview 02
 Difference 2D Design & Dimensional Design 03

2. Market Potential 03

Raw Material Requirements 04

1. Acrylic Sheet 04
2. Aluminium Composite Panels 04
3. 3. LED 05
 What is LED module vs strip? 05
4. Power Supply Drivers 06

4. Manufacturing Process 07

Plant & Machinery Required 07

 Channel Bending Machine 07
5.
 CNC Router Machine 08
 UV Curing Machine 08

Main Design Elements 09

 Colour Selection 09
 Injection- Molded (Plastic) Channel Latter 09
6.
 Standard formed Plastic Letter 10
 Fabricated Metal Letter 10

Internal Illumination 11
 Connection Diagram 12
7.
 Structure 13
 Cost / Estimate 14

Problems with working with acrylic-letter 15

 Mixing powder and liquid 15
 Storage of acrylic dough 15
8.
 Polymerization 15
 Preparation of acrylic teeth surface 15

9. Conclusion 16

Reference 16
 1. Introduction

Durability is what makes the Acrylic Sign Board the best option in signage today. They are
waterproof and weatherproof, made of high-quality cast acrylic, with a classy finish. Acrylic
Signs are manufactured in variations of transparent, opaque and router-cut. Acrylic material
allows light to permeate and hence is used innovatively in signage for light effects like
smudge, smooth and clear.

Sector of consumption – Corporates. Acrylic Letter Sign Boards are presentation boards
designed with multi range of colours and size. Acrylic letters help to suit your organization’s
branding and marketing needs. As these boards are Portable display boards, can modified
with header panels, designed panels sheets, posters.

All letter sign boards packed with sealed box included and are prepared at Designer Site.
Prices from acrylic letter board manufacturing depend upon size and colour of material of
letter boards. Acrylic Board is made from colourless, weather-resistant polymer and
longlasting durable material. Acrylic Signs are perfect elements of traditional glass.
Normally in as Lobby signage, Directional signage and Architectural Signage Acrylic Letter
signs are used and can be applied as Print films attach opaque and clear window screen
decals. 3D Acrylic Letter is Looks awesome for indoor and open-air laser cut or board work.

Page | 1
 Overview
This tech guide is a result of years of hands-on experience with dimensional design,
fabrication techniques, and installation of various signage. It was designed to present
what works and what does not work with dimensional design. Each area involved with
the dimensional design process is revealed. Many ideas presented explain how to avoid
potential problems with planning, design, and even sales. Special emphasis is placed on
the standard conventions and requirements for drawing dimensional signage. This tech
guide will discuss dimensional design with a primary goal of facilitating a design to be
made as intended by a designer. Dimensional design is not the same as graphic design.
This tech guide will cover each aspect of the dimensional design process, including the
hidden variables and factors within the process. Information in this guide is focused on
the basics and standards with reasonable clarity about custom and unique.

Page | 2
  What is the difference? 2D design & dimensional design Dimensional signage
originated in the sign industry. The sign industry makes all of the commercial signage in
a modern society. For example, most retail businesses use channel letters, which is one
type of dimensional letter.
Graphic design focuses primarily on 2D design and related media. Sign design focuses
not only on 2D design, but also on drawing 3D sign products. Letter signage has a goal
which must achieve a purpose: effective communication.
Although signage is considered permanent advertisement, it is much more. Signage is
identity and informational in nature. It is also branding for companies, and is used as
wayfinding for pedestrians and vehicles, among other things. Graphic design, on the
other hand, is primarily focused on medias which result in 2D objects, such as print
media and digital media, all of which are 2D in nature.

2. Market Potential
With the expansion of trade and industry the competition in every field is growing day by day.
After liberalization of economic policy, variety of foreign goods are available everywhere at
cheap rates creating tough competition for industrial and consumer goods in the Local market
and advertisement has become very essential for the success of any business activity. As such
it is found to have scope for starting new small-scale units for the manufacture of Acrylic sign
boards to meet the growing demand.

Page | 3
 3. Raw Material Requirements

1. Acrylic Sheet
2. Aluminium Composite Panels
3. LED
4. Power Supply Drivers

1. Acrylic Sheet :
Acrylic sheet is used in everything from windows and wall partitions to lighting fixtures
and canopies. Acrylic for Transportation Applications– Acrylic is used throughout the
transportation industry in instrument panels, windows, windshields, and mirrors.

2. Aluminium Composite Panels :

The aluminium composite panel is a building material consisting of two aluminium
sheets sandwiching a core material, typically polyethene. Here are some of its properties
and characteristics: Durability: Aluminium composite panels are weather and corrosion-
resistant, making them suitable for outdoor use.

Page | 4
3. LED :
A light-emitting diode (LED) is a semiconductor device that emits light when an electric
current flows through it. When current passes through an LED, the electrons recombine
with holes emitting light in the process. LEDs allow the current to flow in the forward
direction and blocks the current in the reverse direction.

Light-emitting diodes are heavily doped p-n junctions. Based on the semiconductor
material used and the amount of doping, an LED will emit coloured light at a particular
spectral wavelength when forward biased. As shown in the figure, an LED is
encapsulated with a transparent cover so that emitted light can come out.
 What is LED module vs strip?
Whereas individual modules in a series are connected by wires, LED strips are
a continuous row of lights on an adhesive backing — and they're quite thin and
flexible.
LED power supplies are available in both 12V and 24V.

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4. Power Supply Drivers :
LED power sources that provide a “constant-current” output have typically been referred
to as LED drivers. In the past, AC-DC power supplies that provided a regulated
“constant-voltage” to LEDs were referred to as LED power supplies. Today, the terms
“LED driver” and “LED power supply” are used interchangeably.

Page | 6
 4. Manufacturing Process
The first step is figuring out what your sign will say. Then you’ll need to design your
special saying or seating chart on your computer and print them out, cut them up and get
them situated for your sign! For Making one Alphabet of Signage Board, Acrylic sheet
is used in the Channel Bending Machine so that the design of the desired alphabet
produces and then the Alphabets are cut using the CNC Router Machine. After the letter
has been cut, it is sent to the UV Curing Machine for approx. 2 hours. Then, those
alphabets get finishing and LED Lights are installed in them. After Installation of LED
Lights, Wire and Power Supply Testing shall be done for Quality control measures. After
the Proper testing has been done, the Desired Alphabets are packed. Now the Product is
ready to be supplied in the Market

5. Plant & Machinery Required

 Channel Bending Machine

Page | 7
 CNC Router Machine

 UV Curing Machine

Page | 8
 6. Main Design Elements

 Color Selection : Color selection is a simple assessment process that begins with
knowing a dimensional product type. Before a choice can be made, a question must be
asked. Once a project’s parameters are known, color selection is a natural consequence.
There are a few design determinants that should be mentioned in order to dispel any
misunderstandings about color possibilities. A preconceived idea about color is an
impediment with dimensional design. The determinants presented in this section are
intertwined and should be taken as a whole. From the onset of a project, color theme is
of primary importance with design. Equally important is this question,does the choice of
color exist for a dimensional product.

 Injection-Molded (Plastic) Channel Letter. There are eight standard translucent

ACRYLIC face colors available with with an injectionmolded plastic channel letter.
There are 28 standard colors for plastic trim cap. A designer must name a specific finish
on a drawing plan. Just about any manufactured paint color or PMS color may be applied
to a letter return. This type of plastic channel letter simulates the look and appearance of
metal but at a reduced cost. An injection-molded plastic channel letter is inexpensive
because of its manufactured process. This letter type has a deep and hollow return, and
it is also a lightweight product. An injectionmolded letter is a cost-effective solution for
a project requiring an illuminated letter on a budget, however, this letter may also be
non-illuminated.

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 Standard Formed Plastic Letter : There are over 31 standard pigmented colors for a
formed plastic letter. A pigmented color is inherent in a product much like a crayon color.
Like an injection-molded channel letter, a formed plastic letter is also cost-effective. This
letter type is made from a plastic called cellulose acetate butyrate, or simply, CAB
plastic, a renewable material. This plastic letter type is the most popular custom plastic
letter product and maintains a dimensional appearance. A custom created form may be
made for just about any letter style or logo, including original creations. In addition to a
standard choice of hues, a custom paint color may be specified for this letter type without
sacrificing the final appearance. A formed plastic letter is usually non-illuminated, but it
may be specified as illuminated.

 Fabricated Metal Letter : One versatile dimensional letter type comes in several
manufactured versions, each which achieve a different purpose. For a project which
requires a dimensional depth of 1/2" or more, a fabricated letter is possibly the answer.
For a project which requires a dimensional depth with INTERNAL ILLUMINATION,
front-lit or back-lit, a fabricated letter is more than likely the answer.
A dimensional image, such as a logo or graphic, is commonly made as a fabricated
product mostly because of the versatility with color, depth, and purpose. A fabricated
letter type is made and assembled from several pieces, including a thin metal base
support, a metal channel, a plastic face, and a plastic trim cap. A reverse channel letter
with internal lighting components becomes a halo-lit letter.

Page | 10
 7. Internal Illumination
By far, Internal Illumination is the most common lighting source type for a dimensional
letter sign. Up until the year 2010, as a lighting device, a neon tube was the dominate
component used inside a dimensional letter. At the end of 2012, it can easily be said that
a majority of manufactured dimensional letters now use LED lighting components. This
marks a huge transition with lighting devices used with a dimensional letter sign.

Neon provided a lighting solution with dimensional letters for decades. Neon is very
bright compared to LED lighting. When LED modules were first introduced, neon
maintained a more affordable price point than LED lighting. Over time, that changed.
Now that LED modules are more affordable, this technology is much more easy to work
with. To work properly, neon lighting requires high voltage wiring, a transformer, and
must have two electrical leads set through a surface for each dimensional letter installed.

Page | 11
 Connection Diagram :

Page | 12
  Structure :


 Led Module Strip : Width = 10cm

Height = 8cm

 : Width = 9.38inch = 23.82cm

Height = 18inch = 45.72cm
No of Led strip approx. required = 10

 : Width = 19.68inch = 50cm

Height = 18inch = 45.72cm
No of Led strip approx. required = 31

 : Width = 15.7inch = 39.87cm

Height = 18inch = 45.72cm
No of Led strip approx. required = 22

 : Width = 16.5inch = 41.91cm

Height = 18inch = 45.72cm
No of Led strip approx. required = 15

 : Width = 16inch = 40.64cm

Height = 18inch = 45.72cm
No of Led strip approx. required = 14

 Total Number’s of Led Module Strip = 92 + 8 (Extra ) = 100

Page | 13
  Cost / Estimate

Sr.
Material with Specifications Unit Quantity Rate Amount
No.
Led Module Strip
1. ( 12v,1.5w/Module 1 100 9/- 900/-
Waterproof LED SMD )
SMPS
2. 1 1 850/- 850/-
( DC 12V – 150W ,12A )
PVC Unarmored 2 core copper Wire
3. 1 30feet 50/- 500/-
( 1.5mm )
MCB Isolator
4. 1 1 300/- 300/-
( 2-Pole , 16Amp )
PVC Electric Insulation Tape
5. 1 2 20/- 40/-
( Black / Red )
Cable Clips With Metal Nails
6. 1 30 20/- 20/-
( 8MM)
Fevi kwik
7. 1 1 75/- 75/-
(100ml)
8. Double sided tape 1 5 10/- 50/-
10% Extra 273.5/-
Total 3008.5/-

Name and Designation Evaluation Signature

MR. MANISH KUMAR Satisfactory/Not satisfactory

Principal In-charge
BCP, Durgapur

MR. PRONOY DAS CHOUDHURY Satisfactory/Not satisfactory

H.O.D
Dept. of Electrical Engineering
BCP, Durgapur

MR. SUBINOY CHOUDHURY Satisfactory/Not satisfactory

Lecturer
Dept. of Electrical Engineering
BCP, Durgapur

The dissertation has been examined by the evaluation committee and found acceptable.

Page | 14
 8. Problems with working with acrylic resins-
letter
 Mixing powder and liquid : Each acrylic material consists of two components:
polymethyl methacrylate powder with a small content of dibesoyl peroxide
(polymerization initiator) and pigments whose task is to imitate the color of the gums
of the future denture The liquid, or monomer, is a mixture of methyl methycarylate
with a small amount of dimethacrylate (which reduces the solubility and sorption of
the prosthesis made).

 Storage of acrylic dough : The method of storing the mixed acrylic material is also
very important. It should be stirred in a glass or ceramic vessel, after mixing we cover
the vessel with cover, which prevents excessive evaporation of monomer from the
mixture. If the dough becomes excessively dry during storage, it may cause white
lines and discoloration in the interior of the future denture. I dont recommend storing
the dough in silicone dishes, as silicone has strong monomer absorption properties,
which in turn leads to the drying of the entire material.

 Polymerization : Long-term polymerization is very important for thick lower

dentures (thicker than 15 mm). The polymerization cuvette must be placed in cold
water and warmed up gradually. When the denture has a thickness about 15 mm, the
time that has elapsed since the moment of putting the cuvette into the cold water to
boil it should be at least 60 minutes. The water should be heated very slowly

 Preparation of acrylic teeth surface : To obtain a proper connection between the

denture base and the teeth, the surface of the teeth must be properly ground in the
initial period of setting the acrylic teeth in the wax. Sometimes in molars, I make
retention holes with cutters to ensure a better connection between the tooth and
acrylic. After the wax is boiling, and the plaster surface is insulated with an insulator,
it is a time to wash the acrylic teeth surfaces with the monomer. This step is carried
out twice by applying a small amount of monomer to the cervical part of the acrylic
tooth with the help of an ear cleaning stick and rubbing.
Page | 15
 9. Conclusion
Conclusion. 3D printing technology is a major on the original manufacturing technology, which
is slowly changes our production and life, but also plays an extremely important role in cultural
creative design, industry, biological and medical fields

LED gaining popularity in decorative and entertainment lighting The increased popularity of
the energy efficient technologies and green energy has led to a surge in demand for latest LED
innovations across various sectors including hospitality, retail and entertainment among others.

 Reference

1) https://www.flipkart.com

2) https://www.electronicscomp.com

3) www.googleimages.com

4) www.reserchgate.com

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