Introduction

When business owners shop for channel letter signs, they often compare quotes side by side and wonder why the prices vary so widely. One critical, but often overlooked, reason is how the letters are actually built. The manufacturing process matters more than most people realize. At Cobb Sign, we’ve spent nearly a century perfecting our craft, and we’ve seen firsthand what happens when shortcuts are taken.

In this article, we’ll break down the differences between welded channel letters and those that are stapled or glued, and why the choice has a major impact on the longevity, safety, and value of your investment.

What Are Channel Letters?

Channel letters are custom-fabricated, three-dimensional signs typically installed on building exteriors. As the name implies, these have a back plate in the shape of the letter with a piece of channel secured to the edges of the plate and are then covered with a piece of acrylic attached to trim cap also in the shape of that letter. There are also non plastic face channel letters like the ones in the photo above. These have the same back plate and channel set up but with a slightly larger face welded to channel to seat snuggly over the back channel. That particular set also has what is called push-thru acrylic which is made to emulate neon with LED. When assembled, these pieces form the shape of the three-dimensional letter. They are one of the most popular choices for retail, restaurants, healthcare, and franchise brands because they’re highly visible and versatile.

But not all channel letters are built the same way. The construction method makes all the difference.

Cobb Sign's Welded Channel Letters

How they’re built:

• Each piece of aluminum is precision cut on our CNC router table.
• Once the channel pieces are bent to the proper shape, they are welded to the backs and faces respectively.
• The now welded backs and faces of the channel letters are then sanded, washed, and caulked for extra weather protection and mitigation of any potential light leaks.
• After they have had time to dry they are primed and painted.
• The last step is to add LEDs and attach them to raceways (metal housing for power supplies and wiring, typically painted to match the facades exterior) if they are not going to be individually mounted.

Advantages:

• Strength & Durability: Welding creates a bond stronger than the base material itself.
• Weather Resistance: Fewer gaps and seams mean less chance of water intrusion.
• Professional Finish: Smooth, clean joints give a premium look.
• Longevity: Properly welded letters can last 15–20 years with minimal maintenance.

Considerations:

• Welded letters require skilled craftsmanship and more production time, so they can cost more upfront, but they pay off in lifespan and fewer repairs.

Stapled or Glued Channel Letters

How they’re built:

• Instead of welding, some manufacturers use industrial staples, adhesives, or sealants to join materials.
• The goal is to save time and lower costs in production.

Disadvantages:

• Weaker Joints: Staples and adhesives can loosen over time, especially in outdoor conditions.
• Water Intrusion: Gaps at the seams can let moisture inside, damaging LEDs and electrical components.
• Shorter Lifespan: Signs may fail in as little as 3–5 years, requiring costly repairs or replacements.
• Aesthetic Issues: Visible seams or glue lines create a lower-quality appearance.

Why it happens:

• Some companies compete on price alone, and cutting corners in the build process allows them to undercut quotes—but at the expense of the customer’s long-term investment.

Why This Matters for Your Business

Your sign is not just a one-time purchase. It’s a long-term representation of your brand and a daily marketing tool. A welded channel letter system might cost more upfront, but it delivers:

• Fewer service calls
• Better performance in harsh weather
• A professional look that reflects the quality of your business
• Peace of mind knowing your sign was built to last

When comparing quotes, don’t just look at the bottom line. Ask: “How are these letters built?” That question alone could save you thousands over the lifespan of your sign.

Conclusion

At Cobb Sign, we believe in no shortcuts. Every set of channel letters we produce is hand-bent and welded for maximum strength, durability, and longevity. We’ve seen what happens when corners are cut and we know our clients deserve better.

So, welded vs. stapled or glued? The choice is clear: welded channel letters will always outlast and outperform.

‍