How Thermoform Plastic Sign Faces Are Made and Decorated

If you are new to the retail sign industry, then one of the first things to learn about is sign faces —the part of the sign that brings a brand’s identity to life. In the realm of signage, the most popular sign faces are typically smooth (flat on the surface) and painted on the back (2nd surface), or decorated with vinyl applications on the front (1st surface). If you are a retail sign shop, finding a trusted wholesale sign manufacturer is one of the most important steps you can take to establish a domain in your local market for selling plastic faces. More on Hanson Signs below. Back to sign faces.

Thermoforming is a process in which plastic is heated and then pressed or vacuumed onto a mold. When forming a plastic sign face with a sucking/vacuum effect, that is called Vacuum forming. In both cases, you are molding a polycarbonate into a desired shape. These shapes have different styles, sizes, and effects. Let’s take a closer look.

What are smooth PAN sign faces?

Smooth PAN faces are raised and protrude from the sign cabinet body about 2” on average in height. This may be referred to as a “pillow

effect”. Typically, these Smooth PAN faces are decorated with pigmented vinyl (single color), printed graphic vinyl, or painted surfaces. Decoration of the plastic sign faces can be done on the face (1st surface) or the backside of the plastic face (inside the sign cabinet), also known as the 2nd surface.

In the image to the right, the area labelled “COPY AREA” is considered to be the raised smooth PAN area of the sign face. You can also see the raised walls of the PAN face on the side, which some may refer to as the return, can, or pillow. The outer flange is typically the area that inserts into the aluminum sign cabinet and is held in place with retainers.

Decorating Custom Wholesale Sign Faces

Painting: The Most Common Way

The most common way to decorate a PAN face is to paint it. The majority of all plastics are painted on the 2nd surface (back). This is the most common way wholesale sign manufacturers have decorated PAN faces for years. The PAN face to the right started out as a clear Lexan that has been layered with spray paint on the 2nd surface with multiple colors.

First the foreground graphics are sprayed, then the background colors must be sprayed, typically white. The Tricky part of painting PAN faces is that you must layer the paint when spray them to get a nice, consistent, even coat of paint. This takes years of experience.

Benefits to 2nd Surface Paint:

1. Protected Finish – Paint is applied behind the Lexan, so the plastic protects the graphics from scratches, fading, and physical damage.
2. Longer Lifespan – Painted second-surface graphics can often last longer outdoors than vinyl, since they aren’t directly exposed to the elements.
3. Premium Appearance – The depth of color seen through the Lexan creates a smooth, glossy, professional look that vinyl can’t always replicate.
4. Greater Color Range – Custom mixing and layering of paints allows for a wider variety of colors, gradients, and effects.
5. Durability in Harsh Environments – Paint trapped behind Lexan won’t peel, shrink, or lift like vinyl sometimes can over time.
6. No Seams or Overlaps – Large painted areas can be finished without panel seams, which are sometimes necessary with vinyl.
7. More Permanent Branding – Once painted, the graphics become part of the sign face, making them harder to tamper with or remove.
8. Custom Techniques Possible – Special effects (metallics, fades, shading) can be achieved with paint that aren’t possible with standard pigmented vinyl.
9. Better for Complex Designs – Multi-color or detailed graphics can sometimes be executed more precisely with layered paint than with vinyl cutting and weeding.
10. Professional Craftsmanship – Painted sign faces showcase the traditional skill and expertise of wholesale sign manufacturers, which can be a selling point.

Vinyl Application: A Close Second

The second most common way to decorate a Lexan PAN sign face is to simply use pigmented vinyl on the 1st surface (front). Pigmented vinyl is typically a single color vinyl and can be translucent. In this situation, it is normal to utilize a substrate of white Lexan as the background. Standard sizes range from .118, .150, and .177 for larger surfaces.

The vinyl acts as a big sticker sheet that already has the color in it (that’s what “pigmented” means – it has color baked in, not painted on.) A vinyl cutter then cuts.  Then the middles of letters and areas around the shapes are removed. We call that “weeding”.

Next, the cutouts are carefully placed onto the front of the Lexan PAN face. Special tools are then used to help remove as many bubbles as possible. At the end, you have colorful letters and shapes decorated all over your PAN face. Vinyl of this nature is made to last a long time outside in the sun, rain, and snow.

Benefits to 1st Surface Vinyl:

1. Easier to Apply – Vinyl application requires less specialized skill than multi-layer spray painting.
2. Faster Turnaround – Cutting and applying vinyl is typically quicker than masking, layering, and spraying paint.
3. Cost-Effective – Lower labor time and fewer materials (no spray equipment or paint) can reduce production costs.
4. Cleaner Process – Vinyl avoids overspray, fumes, and curing time associated with paint.
5. Consistent Color – Pigmented vinyl has uniform, factory-produced color without risk of streaking or uneven coating.
6. Design Flexibility – Easy to swap colors or update graphics without repainting the entire sign face.
7. Durability – Quality vinyl is UV-resistant and designed to withstand outdoor weather conditions (sun, rain, snow).
8. Repair & Replacement – Damaged or outdated graphics can be replaced by removing and reapplying vinyl, without starting over.
9. Less Training Required – Teams with minimal painting experience can still achieve professional-looking results.
10. Reduced Equipment Needs – No need for paint booths, sprayers, or ventilation systems.

Note on Sizing: Keep in mind that Thermoformed smooth PAN faces do have size restrictions. The maximum size that can be produced often depends on the equipment and capabilities of your wholesale sign manufacturer. Always check with your supplier before proceeding to ensure your project can be manufactured to the required dimensions.

At Hanson Signs Co., we have 6 core products, including plastic sign faces. Our plastic department has the shortest lead times and 95% on-time delivery. If you need a quote for a custom wholesale thermoformed plastic sign face, then we would love to help you out.

Submit your quote today or call 800-522-2009 with questions.