DiBond Signage - Tips & Tricks
Share
How to Streamline Your Dibond Sign Production Process (From 3 Years of Hands-On Experience)
If you’re trying to produce your own Dibond signs and want to streamline your workflow, this guide is for you.
At Ztrange DeSigns, we’ve been producing Dibond signage for over three years. Along the way, we’ve made mistakes, refined our processes, upgraded equipment, and learned what actually works in a production environment. Below is a breakdown of what we’ve found to be the most efficient and reliable approach.
What Is Dibond?
For those unfamiliar, Dibond is a rigid composite panel made from two thin aluminum outer layers with a polyethylene core in the middle. This structure makes it lightweight, strong, weather-resistant, and extremely versatile.
Dibond is commonly used to manufacture:
-
Flat panel signs
-
Channel letters
-
Backlit acrylic signage
-
Cabinet sign shells
-
Architectural signage
The two most common thicknesses are:
-
3mm (most common)
-
6mm (used for heavier-duty applications)
Material Sizing & Cutting
We purchase Dibond in 4' x 8' sheets and cut them down to size using our Laguna MT Elite CNC router.
If you don’t have access to a CNC, Dibond can also be cut using a saw equipped with a metal-cutting blade — but CNC routing provides far greater accuracy and repeatability.
CNC Bit Selection Matters (A Lot)
When cutting Dibond on a CNC, we’ve found that bit selection is critical.
Our Recommended Bit:
Spiral O Single Flute – Aluminum Cutting Bit
This bit works extremely well whether you’re cutting:
-
Straight panels
-
Routed letters
-
Complex shapes
What Happens If You Use the Wrong Bit?
Early on, we made the mistake of using a ball nose bit on a cabinet sign project. While it appeared to cut correctly from the top, it left the bottom aluminum skin partially attached. This caused cleanup issues and ruined production efficiency.
Since then, we’ve become much more intentional about matching:
-
Material type
-
Bit geometry
-
Feed rates
-
Depth settings
Understanding tooling is one of the biggest productivity upgrades you can make.
File Preparation Using VCarve
We use Vectric VCarve software to generate our CNC toolpaths.
This allows us to:
-
Create clean vector cut paths
-
Set precise cut depths
-
Control lead-ins and tool direction
-
Optimize job layout
Once the panel size is finalized and the toolpaths are created, we’re ready for printing.
Printing on Dibond: Two Methods
Traditional Vinyl Application (Still Works)
For years, we used:
-
3M IJ180 vinyl
-
3M Scotchcal Gloss Overlaminate 8518
After printing, the vinyl was applied to Dibond using our roller application table. This process still works great and is widely used across the industry.
Direct Printing with HP R2000 Flatbed (Our Current Workflow)
Last year, we invested in an HP R2000 flatbed printer, and it completely changed our Dibond production workflow.
Now we can:
-
Print directly onto rigid substrates
-
Skip vinyl application
-
Save labor time
-
Improve consistency
Printing Process:
-
Load the Dibond substrate profile
-
Place material on the bed
-
Import artwork
-
Print directly to panel
Important Printing Tips (Avoid Costly Mistakes)
1. Dibond Isn’t Always Perfectly Flat
This is critical.
We manually raise the scan beam by 0.02 inches above measured thickness to prevent print head contact. This small adjustment protects your machine and avoids catastrophic damage.
2. Image Alignment & Bleed Settings
If you’re using bleed:
-
Center the image both vertically and horizontally
-
Avoid left or right alignment offsets
-
Confirm bleed settings are enabled
Misalignment issues are one of the most common production errors we see.
Laminating for Protection (Highly Recommended)
After printing, we move the panel to our roller table and apply 3M Overlaminate 8518.
While this step isn’t required, we strongly recommend it when the client’s budget allows.
We explain to customers that:
-
Lamination protects their investment
-
Extends outdoor lifespan
-
Improves UV resistance
-
Adds scratch protection
Most clients appreciate the added durability.
Final Steps: Packaging & Quality Control
Once the sign is complete:
-
We protect it with custom packaging
-
Build custom boxes using CNC or laser when needed
-
Run every job through our internal quality check system
Each project is logged digitally and reviewed before leaving the shop.
This step alone has drastically reduced rework and client complaints.
Final Thoughts
Producing Dibond signage efficiently takes more than just equipment — it requires:
-
Correct tooling
-
Smart workflow decisions
-
Quality control systems
-
Continuous learning
We hope sharing our real-world experience helps other shops avoid costly mistakes and improve their production process.
If you’d like to follow more of our wins, failures, and lessons from the print shop floor, be sure to stay up to date with our blog.
Thanks for reading — and happy fabricating.