Vacuum-Formed Sign Faces
for Pole and Pylon Signs

Vacuum-formed and pan-formed faces for pole and pylon signs are a proven, classic solution that provides superior wind resistance and dramatic 3D appearance.

Before flexible face material existed, the only reliable way to keep large plastic faces from breaking or blowing out in the wind was to form reinforcing ribs into the sheet. The strongest and best-looking method was to raise the lettering and create a raised border around the edges.

This was especially critical with Lexan®/polycarbonate because flat sheets are soft and bow or blow out completely in even moderate wind.

Today most large pole and pylon signs use flexible vinyl faces, so true vacuum-forming is uncommon. Shallow “blister” forming (2–3 inches deep) is sometimes used on low-cost signs simply to clear internal lamps, but it is widely regarded as cheap-looking and is reserved for secondary/program signage.

True deep vacuum-formed and pan-formed faces still deliver the premium, high-end look that flexible faces cannot match.