Shortly after receiving your order we create a proof with the lettering you want on your sign. The proof is essentially an accurate to-scale drawing of your design. When finished, stencils are produced according the outlines of the proof. The stencils are thin cardboard sheets with the letters and ornamental details of the design cut out.
A pre-cut, drilled and arched steel plate in your specified size is rinsed and carefully inspected for faults. It is crucial that the steel backing is 100% clean and free of any grease or defects before the enamelling process begins. Enamelling is a ceramic process, much like glazing ceramics. Initially, the grey enamel primer is applied, the sign is left to dry, and then fired at 820°C (1500°F) for 8-12 minutes. After the firing, it is left to cool. During the firing process, the enamel bonds chemically to the steel, to create a base layer. After the base layer has set, the background colour of the sign (for example blue) can be applied in the same manner. Finally the foreground colour is then applied and dried. Using the prepared stencils as guides, the final layer of powdered enamel is placed on the signs; any excess enamel is carefully brushed away by hand to ensure precision lettering. The sign is then fired for the last time. In fact, the sign is fired in a kiln at 820°C (1500°F) and inspected for defects between each enamelling. To ensure an energy efficient production and a consistent quality, the signs are enamelled and fired in batches throughout the entire production.
