Carved Signs

Our carved signs are made from High Density Urethane (HDU). This material is more accurate to carve than traditional wood, and it is more resistant to harsh outdoor conditions including fluctuations in temperature and humidity.

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Uses

Carved HDU (high-density urethane) signs are a popular choice for businesses andorganizations that want a dimensional, high-end look without the drawbacks oftraditional wood. HDU is a rigid foam material that can be carved, routed, and shapedwith precision, allowing for deep textures, raised lettering, and intricate designs. You’lloften see these signs used for storefronts, office parks, residential communities, parks,and wayfinding systems. Because the material is so versatile, it works just as well forclassic, hand-crafted styles as it does for clean, modern branding.

Benefits

One of the biggest benefits of HDU is durability. Unlike wood, it doesn’t rot, warp, orcrack when exposed to moisture. It also resists insects and holds paint extremely well,which means colors stay vibrant longer with less maintenance. HDU is lightweightcompared to solid wood or metal, making it easier to handle during fabrication andinstallation. At the same time, it’s dense enough to feel solid and substantial, so it stillgives that premium, carved look people expect from dimensional signage.

Installation

Installation is usually straightforward, but it depends on the size and location of the sign.Smaller wall-mounted signs can be attached directly to a building using screws ormounting brackets. Larger monument-style signs are often installed with posts set inconcrete or mounted to a structural frame. Because HDU is lighter than many othermaterials, it puts less stress on mounting hardware and support structures. Still, properinstallation matters. A secure base, level positioning, and weather-resistant fastenerswill help ensure the sign stays stable and looks professional over time.

Care

Caring for a carved HDU sign is relatively simple. Routine cleaning with mild soap andwater is usually enough to keep it looking fresh. Since the material doesn’t absorbwater, there’s no need to worry about swelling or decay. Over time, the painted finishmay show normal wear from sun exposure, especially in harsh climates. When thathappens, a light sanding and repainting can restore the sign’s appearance withoutneeding to replace the entire piece. With basic upkeep, an HDU sign can last for manyyears while maintaining its visual impact.

Frequently Asked Questions

What is a carved sign?

Carved signs are signs in which letters and logos are carved into the substrate. In our earlier years, carved signs were made by hand. Today, sophisticated CNC (Computer Numerical Control) machines are used to make all of our carved signs.

What materials are used to make carved signs?

There was a time when all carved signs were made out of wood, but today almost all carved signs in the United States are made from high density urethane (HDU). It is a hard, closed-cell polyurethane foam board offering the look of wood, but with superior durability, versatility, and resistance to moisture. This rigid substrate will not rot, warp, or crack.

How are they made?

Letters and logos are carved into the substrate (usually HDU) with a CNC router machine. Once the design is completely carved, a full 1-week painting process begins. Once the undercoat is perfect, we spray several coats of clear to ensure longevity and protection from UV rays.

What finishes are available?

Elmark Sign Company commonly finishes carved signs with flat, satin, or gloss paint. For a special flair, some clients will select imported gold leaf for lettering, logos, or other aspects of their sign.

What sizes are available?

Elmark Sign Company has built signs wider than 15 feet and/or over 75 square feet.

Can a carved sign have raised graphics?

Yes, a carved sign can have raised graphics through a technique called relief carving. In relief carving, the background material is carved away, leaving the letters, images, or designs raised above the surface of the sign.
More commonly, carved signs are routed to create incised letters or graphics. Incised letters or graphics are carved into the high density urethane.

How are carved signs installed?

Carved signs are frequently post-mounted, wall-mounted, or hung from a scroll bracket. Elmark Sign Company has some clients that have installed carved signs into masonry monument signs as well.

How much do carved signs cost?

The price varies by complexity of design and thickness of material. On average, products costs range from $250 to $350 per square foot, measured from a single face of the sign.

How long do they take to make?

Carved signs generally take 2-3 weeks to deliver.

What makes Elmark Sign Company's carved signs the best?

Through a proprietary painting process we’ve developed over 4 decades, our HDU carved signs are hand sanded and primed several times before applying the first, of three coats of paint. After ample curing time has passed, we finish the sign with 3-4 applications of clear coat. The result is a superior finish, which resembles that of a brand new car.
We are so confident in our work, that we offer a full, 5-year warranty on all of our signs (5 times the national average).