Cabinet-Style Dibond LED Sign Fabrication
Project Debrief: Cabinet-Style Dibond LED Sign Fabrication
As we continue refining our in-house signage capabilities, this cabinet-style Dibond LED sign project offered an excellent opportunity to combine multiple fabrication methods into a single build. The goal was to create a durable, professional-looking illuminated sign that functioned as both a structural cabinet and a visual display, while also pushing our understanding of spacing, lighting, and internal construction.
This project brought together CNC routing, laser cutting, and LED integration — and, just as importantly, highlighted where thoughtful planning makes all the difference.
Design Concept & Material Selection
The design centered around a cabinet-style sign, meaning the sign has depth rather than being a flat panel. This approach allows internal components like LED lighting and wiring to be housed cleanly, while also giving the finished sign a more dimensional, premium appearance.
For the cabinet structure, we chose Dibond due to its rigidity, durability, and clean finish. Dibond is an ideal material for cabinet-style signage because it resists warping, machines well, and provides consistent results when cut on a CNC.
For the illuminated elements, 1/4 inch opaque acrylic was selected for its light-diffusing properties. When paired correctly with LED lighting, acrylic produces an even glow and eliminates harsh light spots — making it a go-to material for backlit signage.
Fabrication Process
The Dibond cabinet components were cut on our Laguna Elite MT CNC router paired with our V-Carve software, allowing us to achieve accurate dimensions and clean, repeatable cuts. CNC routing ensured that the front, back, and side panels aligned properly during assembly, which is critical when building any cabinet-style sign.
We used a Amana Tool 45792 V-Groove 90 Deg bit to score the edges of our dibond. This helds create a 45 degree fold that we can secure together for clean durable edges.
Precision at this stage helped reduce material waste and minimized the need for rework later in the process.
The acrylic components were cut using a Boss LS 3655 laser engraver, which provided the level of detail and edge quality required for illuminated elements. Laser cutting ensured smooth edges and precise shapes without the need for extensive post-processing — an important factor, since imperfections in acrylic become far more noticeable once lighting is introduced.
LED Integration & Assembly
With the structural and acrylic components complete, we moved on to LED integration. The acrylic was positioned to diffuse the light rather than expose individual LED points, which is essential for achieving a clean, professional glow.
During assembly, we identified an issue with spacing and tolerances between the front and back cabinet pieces. While the components fit together, tighter tolerances made assembly more difficult than necessary and left less room for wiring and LED placement.
This reinforced an important lesson: cabinet-style signs require just as much attention to internal layout as external appearance.
Challenges & Areas for Improvement
One of the main challenges was achieving consistent light distribution across the sign. Without additional internal support, the LED strips did not sit as evenly as intended, resulting in uneven illumination in some areas.
This led us to recognize the need for foam frames or internal supports to properly seat the LED strips. Adding these supports would:
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Maintain consistent spacing between LEDs and acrylic
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Reduce hotspots
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Improve overall light diffusion
Another takeaway was the importance of designing internal structure early. While the exterior cabinet looked clean and professional, the internal layout required refinement to improve both functionality and ease of assembly.
Lessons Learned & Future Improvements
This project reinforced the value of detailed planning when combining CNC routing, laser cutting, and LED integration. In future builds, we plan to:
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Refine sizing between front and back cabinet components
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Incorporate foam frames or internal supports for LED placement
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Allow additional space for wiring management and maintenance
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Prototype internal layouts before final cutting
These adjustments will streamline production and improve the consistency and quality of the final product.
Conclusion
Overall, this cabinet-style Dibond LED sign was a successful build and a valuable learning experience. The finished sign achieved the intended illuminated effect and demonstrated the effectiveness of combining CNC machining, laser cutting, and LED technology in a single project.
More importantly, the project highlighted where small design and planning improvements can significantly impact both build efficiency and final quality. With refinements to spacing, internal structure, and LED support, future versions of this sign will be easier to produce and deliver an even higher-end finish.
As with every project, each build helps us refine our process — and that’s what ultimately leads to better signage for our clients.