1. Set up file for mask cutting - No matter how simple a sign is or how fine a customer delivers a file, there is almost always some form of technical set up involved to prepare the file for production. This may involve eliminating extra lines that will cut or resizing to actual dimensions of the finished sign.
2. Cut substrate material to size - The material must obviously be cut to finish size. A routed shape requires even more set up time and effort to acheive the desired shape requested by the customer.
a. Sand edges smooth
To eliminate unsightly cut lines from the edges of the material, the sides of the material are sanded after the substrate is cut to size.
3. Prime substrate - In order for the sandblast stencil material to optimally adhere to the substrate, a coat of primer paint must be applied and allowed to thoroughly dry.
a. Sand surface to better accept mask material
Any raised particles in the surface coat of primer paint must be eliminated through a light sanding. This is to ensure that the sandblast stencil has the best bond to provide for a clean blast.
b. Sand and fill any irregularities.
Any scratchs or dents are eliminated through the use of a filler material that results in a smooth, clean surface. This is done to ensure that unblasted areas do not have any noticable flaws after the sign is painted.
4. Cut/weed sandblast mask stencil - The sandblast mask is cut on a cutter similar to a typical vinyl cutter; and just the same the mask must be "weeded" to provide for blasted areas of the sign. The blasted areas are discarded while the areas that will appear "raised" remain.
5. Apply sandblast mask material to substrate - The sandblast mask is then applied to the surface of the substrate. Care is given to make sure the mask is squarely aligned. The edges of the sign are covered with duct tape to protect them from exposure to the sandblast abrasive.
6. Sandblast the sign -
Finally, the sign is ready for the sandblasting step.
The good news is; the sign is finally being blasted.
The bad news is; the sign is still only half way to completion.
7. Remove mask stencil - Of course, following the blasting steps, the mask is removed and the sign is cleaned of sand residue and prepared for painting.
8. Apply ArmorSharp protective coating - Next, SharpSigns applies the rock hard primer, ArmorSharp. This two-part resin primer cures within 48 hours to form a hard, protective shell. This is a critical step in preparing the sign for long life duration of the sign.
a. Sand and fill any irregularities.
At this point, SharpSigns also cleans the sign of any irregularities that may result in an unclean finish paint coat. Any holes or irregularities are prepared for final paint coats.
9. Mix paint colors if so required to match specs - Typically, SharpSigns uses 1-Shot brand enamel paints. If the customer has specified a paint color that is a custom color (such as a Panatone color), SharpSigns hand mixes the paints to best match the color specified.
10. Spray background paint color - The background paint is sprayed on after the color is best-matched. It is critical to have a clean, fully dry paint coat at this point. Any instability in the base coat will result in problems with each successive layer of paint that follows. For best results, this background is allowed up to 48 hours to fully dry.
11. Handpaint lettering, borders and details with 1-Shot brand enamel paint - All of the lettering and graphics are hand-painted to create the quality finish provided by good old fashioned attention to detail. This step can be quite time consuming in order to give the customer the finest results. Any runs, drips or flaws are touched up in the final steps of painting. Again, SharpSigns must allow up to 48 hours to allow for a completely dry finish paint coat.
12. Prepare crate and arrange shipping - In nearly all cases, the sign is shipped in a wooden crate. Since sign sizes range in great numbers, each sign has a crate made specifically for that order. Custom crating ensures the sign fits best for ideal shipping conditions.
13. Pack sign and touch up paints - Extra touch up paints are also gathered and packed to make the installation easier for the customer.
14. Load on shipping dock - Shipping arrangements are made for the most cost-effective and timely delivery of the sign. Tracking numbers are collected when possible in order to keep the customer notified of en route progress.