Step by Step manufacture of an illuminated pylon

Illuminated Pylon

This is the first time we have made a post of this kind and we hope you like it. Compac manufactures many fabricated pylon signs of all shapes and sizes. There are certain things to consider before manufacture to ensure the project runs smoothly.
In this case we will outline the steps taken to produce an opal acrylic illuminated, ACM wrapped, fabricated steel pylon.

  1. Survey
    All jobs begin with a survey. Installation locations need to be surveyed to ensure there are no objects that will obstruct the operation of the crane or that the ground is solid and flat enough for the crane to operate. In the event of illuminated signage (unless solar powered) a power source must be identified close to the pylon. Concrete foundations or footings must also be considered as land will need to be excavated at the install location.
  2. Design
    There are a few stages involved at the design process. CAD, CAM, electrical and graphical.
    CAD drawings are designed to exact dimension for engineer approval. Most large structures will need be approved by a qualified engineer. The internal structure can then be fabricated as per the technical drawings.
    Meanwhile, the graphic design will occur. The designer will consider typography, balance, colour and corporate style guides and branding.
    CAM drawings will be extracted from the CAD drawings to be sent to the CNC router. This machine will router the aluminium composite material (ACM) that will wrap the internal structure, and the acrylic back-lit letters. In some cases, electrical plans will also need to be drawn and assessed by a qualified electrician to ensure safety.
  3. Print
    If company branding is required the necessary items will be printed to self-adhesive vinyl and wrapped around the ACM panel.
  4. Cut
    Once the panels have been wrapped, they are ready to be routed. ‘V’ grooves will be cut into the material and allow it to be folded to suit the fabricated structure and fixed using special adhesives. Female cuts are applied to the text area (where required). These are generally 0.5mm larger than the acrylic that will be “pushed” through. The acrylic letters are generally 10mm+ in thickness to allow a generous profile once we have compensated for the thickness of the ACM. In the case of illuminated opal (or opaque) acrylic is used to allow for the light to be dispersed through the product.
  5. LED
    LED modules will be fixed in an array to a panel inside the structure but behind the illuminated area. The arrays will be prepared for connection to the external power source at site location.
  6. Quality Control
    Prior to leaving the factory a quality control team member will check the panels and prints for any defects and the LEDs illuminate as expected.