Whether you’re crafting bold retail signage or sleek architectural letters, the bending process forms the backbone of channel letter manufacturing. Channel letter bending is one of the first steps in turning raw aluminum coils into channel letter returns that give signs their signature 3D shape.

This post breaks down the fundamentals of channel letter bending – specifically notching, flanging, and bending – and shows how channel letter automation is transforming this once-laborious task into an efficient, high-output process.

What Is Channel Letter Bending?

Channel letter bending refers to the process of forming the channel letter returns for signage from aluminum coils. It’s the heart of channel letter fabrication. Traditionally done by hand with brakes and snips, today’s process is almost entirely automated thanks to specialized machines like the Accu-Bend product line.

At the core of the channel letter bending process are three key functions:

• Notching
  
• Flanging
  
• Bending

Let’s explore each one and why it is essential to channel letter bending.

Step One: Notching – Making the Channel Letter Bendable

The first challenge in shaping aluminum coil into channel letter returns is controlling where it bends. That’s where notching comes in.

A notch is a precisely cut groove in the aluminum coil that tells the machine, “Here’s where to bend.” It removes just enough material to allow a tight, clean corner without distorting the face or flanges. Proper notching ensures consistency across complex letterforms – especially those with sharp angles or tight curves.

In automated systems like the Accu-Bend product line, the notching process is controlled by specialized Accu-Bend software. That means each notch is placed with sub-millimeter precision, following the letter design imported from the software. No guesswork. No uneven bends. Just clean, professional results every time.

Step Two: Flanging – The Invisible Backbone of a Channel Letter

Flanging is the process of forming a lip or edge along one side of the aluminum strip – usually the inner edge that will be bonded to the channel letter’s face.

This flange is crucial. It adds rigidity to the letter return and provides the surface needed to attach the face of the channel letter. Without a clean, uniform flange, your channel letters won’t align correctly or maintain their shape over time.

In machines  like the Accu-Bend Stingray, flanging is integrated directly into the production workflow. As the coil feeds through the Accu-Bend machine, the flange is formed in a continuous pass, resulting in consistent channel letter returns that snap perfectly into place during final assembly.

Step Three: Bending – Bringing the Channel Letter to Life

Once notched and flanged, the coil is ready for the signature step: bending.

Here, the flat aluminum is guided through bending arms that physically shape it into the vertical walls of the channel letter. Every curve, corner, and contour is translated from the design file into its physical form – accurately and repeatedly.

The Accu-Bend Freedom, Computerized Cutters’ compact table-top channel letter bender, is one of the machines that automates this step with ease. It can complete a standard channel letter in minutes – far faster than even a skilled manual-bender – making it ideal for sign shops with tight turnaround times, a moderate budget, and limited space.

Automation isn’t just about speed, though. It’s about consistency and repeatability. When the same letter has to look the same every time – whether it’s one sign or one thousand – that level of consistency only comes from the best: Accu-Bend channel letter bending machines.

Why Automation Matters in Channel Letter Fabrication

Bending channel letter returns by hand is slow, requires skilled labor, and introduces variability into every sign you produce. For sign shops trying to scale or maintain a competitive edge, manual channel letter bending simply doesn’t cut (or dare we say bend) it anymore.

Automated channel letter bending machines offer several advantages:

• Speed: Complete letters in minutes, not hours.
  
• Accuracy: Specialized automation software ensures precise angles and flawless flanges.
  
• Labor Efficiency: Operators don’t need years of experience – just a few hours of training.
  
• Scalability: Produce dozens to hundreds of channel letters per day without added staff.
  
• Cost Reduction: Slash outsourcing and reduce material waste.
  

Every Accu-Bend model is designed to deliver these benefits in different ways – from the affordable, tabletop and compact  Accu-Bend Freedom to the power of the industry’s powerhouse, the Accu-Bend Stingray.

Matching the Right Channel Letter Bender to the Job

When choosing a channel letter bending machine, consider your volume, materials, and size range of your channel letter(s).

• Small shops or new entrants? The Accu-Bend Freedom offers an affordable entry point with compact power.
  
• Shops needing .063” aluminum support? The Accu-Bend ACE+ adds heavy-duty capability without an expensive price tag.
  
• High-volume manufacturers or those crafting large, reverse-lit, halo-lit, or trimless channel letters? The flagship Accu-Bend Stingray is the industry’s newest and fastest powerhouse channel letter bender capable of producing over 150 channel letters per day* with the smallest, sharpest, and most accurate bends to date.
  
  *These numbers vary depending on the size and complexity of the channel letters being made.

No matter which option you select, each Accu-Bend channel letter bending machine notches, flanges, and bends in one continuous operation – best for maximizing productivity and precision across the board.

Final Thoughts: Craftsmanship Meets Automation

At its core, channel letter bending is an art form. Every sign is a visual signature of a brand or message. But craftsmanship doesn’t have to mean slow, manual work. With the right machines, artistry and automation can coexist – yielding high-quality channel letters that are faster to produce, easier to assemble, and more profitable to sell.

Whether you’re just exploring channel letter automation or are ready to upgrade your entire workflow, mastering the fundamentals of notching, flanging, and bending is the key to unlocking the next level in sign-making. And we at Computerized Cutters have the best channel letter bender solutions to achieve just that. 

Ready to Automate Your Sign Shop?
Get Pricing or call (972) 422-6900 to learn how the Accu-Bend channel letter bending machines can transform your sign shop’s efficiency and output.