Channel Letter LED Strip Lighting for Signs
A fabricated letter is a shallow metal box with a translucent face, and the light inside cannot hide. Channel letter LED strip lighting has to fill that box evenly from a source the viewer never sees, at a return depth often only three or four inches. Get the spacing and setback right and the face reads as one flat plane; get them wrong and it shows stripes, blobs, or dark tips on an S.
How channel letter LED strip lighting fills a letter evenly
Light spreads in a cone. A face is only evenly lit when those cones overlap before they reach it, which makes return depth against emitter spacing the whole game. A shallow return needs sources closer together than a deep one, since the beams have less distance to merge.
Continuous tape has an advantage over spaced point sources: along the run there is no gap to overlap. A dot free COB line in a wide stroke gives a smoother wash than separated emitters at the same depth.
Depth, spacing, and the letters that cause trouble
Run tape along the inside of the return, following the letter outline, so light crosses the cavity rather than facing the acrylic. Wide strokes need a second run on the opposite return, and open counters may need a line across the back as well.
The problem characters are always the same. Tight radii on an S, the apex of an A, and the counters in an O all trap light or starve it. Bend a run only to the product's stated minimum bend radius; where a corner is tighter, cut and rejoin. Many strips allow cuts at designated points, with reconnection by compatible connectors or by soldering, depending on the product, so confirm the cut interval and bend limit before fabrication.
Paint the inside of the can flat white first; bare aluminum reflects unevenly and shows as a hot line through a thin face.
