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I may be wrong (wouldn't be the first time), but the only manufacturers in that market that I'm aware of were HP and Mimaki. Last time I looked was a while back, but they were it as far as anything of any size that might actually be usable for a sign shop.
Reverse print on clear and laminate with white for some opacity (use translucent if you want more light coming in/out) and apply to interior. If it needs to be perf, I seem to recall some manufacturer had come out with a perf that worked for second surface, but don't remember who it was.
I suggest not using ACM for a backer. I don't have anything against ACM, mind you- it's just that that's a pretty sizeable backer to have relying on a couple of pieces of tin-foil and plastic to keep the fasteners in place. I've seen plenty of ACM signs pulled off walls, posts, etc. when a stiff...
Hate to disparage, but that's either not a very good router, or not a very good operator. Our router cuts on plastics almost never require finish work, and we do a ton of push-thru (have 14 sheets' worth for just one order waiting for assembly at the moment).
^^^ This right here. My favorite example of this is a job I had back in the 80s at an industrial supplier. Every single one of the folks working as salespeople and CSRs had to have worked in the shop (actually assembling the products) before the boss even considered pulling them into the office...
I couldn't even venture a guess as to how many times I've had to kick back orders calling for 1/4" stud-mounted acrylic. At least with aluminum, you can "cheat" and go a little deeper with a finer thread.
You can do the refining of your font in Illustrator, but it won't create a font file. You need a different program for that.
Pretty good tutorial here.
It's ridiculously hard to find on the SAI website, but Gunner isn't listed in the most recent version of Flexi as far as I can tell. Try contacting either Gunner or SAI directly to ask them.
White is what we go with nearly universally, because then the customer won't complain that they can see the LEDs along the edges (when you get the right angle, they're glaringly obvious). This keeps you from having to adding yet another layer of vinyl- the diffuser they're going to want on the...
Haven't personally touched one in a minute, but- from the description you fond via Google- yes, they are. Probably with some extra coatings and abrasion resistance, but the inner lining and canvas sound exactly the same.
Outwater Plastics and MBS Standoffs spring immediately to mind. They have all kinds of stuff you wouldn't expect, and both carry a variety of mounting brackets, holders, etc.
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