Any Idea how to do this

[Signsup]

A customer would like a layered sign. Cut out rust on top a gray steel background. I do not see hao to do this as there are a ton of tiny pieces that would need to be attached to the bottom layer. How would I go about this. Is there some sort of laser material out there? I asked them if it could be simplified and ended up agreeing that I would see if it can be done.
This is out of our wheelhouse.

 

[pro-UP]

How large do they want it? Is it interior or exterior?

 

[John_Smith]

Why metal?
For me, I would cut it out of 1/4" wood with a scroll saw and paint it a faux rusted metal. (it ain't rocket science). It's Craftsmanship.
Much more information would be nice.

 

[Gino]

If it's outta your reach, just turn it down ans say you're sorry

 

[White Haus]

How large do they want it? Is it interior or exterior?

Crucial information required.

 

[Think713]

A customer would like a layered sign. Cut out rust on top a gray steel background. I do not see hao to do this as there are a ton of tiny pieces that would need to be attached to the bottom layer. How would I go about this. Is there some sort of laser material out there? I asked them if it could be simplified and ended up agreeing that I would see if it can be done.
This is out of our wheelhouse.
View attachment 183039

As mentioned above, how big is going to matter. Plus you're talking about steel. I designed a sign like this for a neighborhood that was being build by orange capital advisors, and they didn't even wanna pay what it would cost. If you're going to build something like that, you're talking a 50-60,000$ sign to the customer. Just the steel sheeting alone is going to run you thousands, and theyre incredibly heavy.

 

[Think713]

Why metal?
For me, I would cut it out of 1/4" wood with a scroll saw and paint it a faux rusted metal. (it ain't rocket science). It's Craftsmanship.
Much more information would be nice.

That wouldn't be a bad idea. these days you can get pretty close with a good creative finish.

 

[John_Smith]

That wouldn't be a bad idea. These days you can get pretty close with a good creative finish.

That's what I do - dimensional signs - "with a pretty good finish".

 

[Kev-O-Rama]

Given the limited details, if it were me, I'd ask if it would be okay to 86 the small pieces of the tree for the sake of the CNC table and acquire some faux oxidized steel laminate from Chemetal (#607) for the rust and laminate it to a substrate either for added thickness or to serve as a spacer between the gray substrate.

But given I'm also a former scenic artist, I can see John Smith's (If that's your real name, lol) argument and paint it by hand after it's cut. I've done a zillion faux rust scumblings. It really depends on interior/exterior/region/sun exposure/substrate/budget/skills, etc.
If you use acrylic for the tree substrate, then you can laser cut it & paint faux rust, but save the drop, as it will serve as your template if you Weld-on all the little pieces of the tree to perhaps a P99 clear laminate. My 2¢

 

[citysignshop]

Hahhaha.....wait....this is TOO funny! you have some ARCHITECTS....who write specifications for their Breakfast, asking you to do a sign 'just like this'. So they had someone do it before...find that PO, or ask them who did it! Then order another one, mark it up 400% like they do, and take the rest of the week off!
....glad to help!

 

[Ron at Forest Litho]

If it's outta your reach, just turn it down ans say you're sorry

If you find a printer who can do it, You may decide that you don't want to get caught in the middle just for a mark up. So you might say "Sorry this sign is not my thing ... but you can try this guy... I think he can do it." That way you are still someone your client will call in
the future.

 

[Ron at Forest Litho]

Hahhaha.....wait....this is TOO funny! you have some ARCHITECTS....who write specifications for their Breakfast, asking you to do a sign 'just like this'. So they had someone do it before...find that PO, or ask them who did it! Then order another one, mark it up 400% like they do, and take the rest of the week off!
....glad to help!

I just had a similar situation. A client wanted to give me his business, But I found out that he had it done last time by someone who still had all the files and there were no changes. So I told him I appreciated the thought, but he should just give the little job to someone who already had it all set up!

 

[Signsup]

Thanks for the reply. She wants the sign 4' x 6'. Using the CNC might be the best way to go. She has very specifically requested Corten steel on brushed aluminum. She wanted to know if I would weld all the little pieces onto the sign. I have to figure out how to communicate in a way we do not lose the job. That we can come close to the look she is after if we change the art and approach. Losing the job is okay. But it is frustrating when a customer asks for something that does not really work and they end up going somewhere else and doing what you suggested as an alternative.

 

[JBurton]

Sheesh, gemini would do this. Just did a tree with 345 individual cut leaves, cut the pattern on the background with the CNC, painted, then individually mounted all of the leaves. It was excruciating, especially trying to read the numbers on the back of all the pieces, some being 1/2"x1/2" or smaller. I'll get a picture of the back side of the sign for y'all, it was nuts. Worst part was driving the locknuts onto the 8-32 studs without twisting the stud in half, should have spec'd steel studs.

 

[JBurton]

 

[Goooost]

Maybe it would be possible to take a black core dibond and CNC engrave it deep enough to get through the metal and reveal the black core without going all the way through.
the rust could just be a texture you flatbed print beforehand.
Otherwise that's going to be a nightmare.
If I had to do it here with my equipment, I'd end up printing that rusted texture onto vinyl and either do a contour cut+weeding or a white ink print on clear vinyl, then mount that to a clear backing and have my black underneath that to achieve that raised effect.