Cost Estimate for Large Channel Letter Signs in India

(Charged Per Square Inch – Industry Standard Guide)

In the Indian signage industry, channel letters are almost always calculated per square inch, rather than per running foot, per letter or by guesswork.
If you are planning a large façade sign for a showroom, mall, hospital, factory or highway restaurant, understanding per square inch costing will help you negotiate properly and avoid confusion.

Let’s break it clearly in the Indian context.

What Are Large Channel Letter Signs?

Large channel letters are 3D fabricated illuminated letters made using:

• Aluminum side returns (body frame)
• Acrylic front (brand color face)
• Internal LED modules
• Back panel (ACP / aluminum sheet)
• Power supply & wiring

For large-sized letters (2 ft, 3 ft, 4 ft and above), structure strength and LED layout become very important.

How Channel Letters Are Calculated (Per Square Inch Method)

In signage fabrication total cost is calculated as:

Letter Height × Letter Width = Total Square Inches
Total Square Inches × Rate per Square Inch = Fabrication Cost

Example:
If one letter size is

• Height: 36 inches
• Width: 28 inches

Then:
36 × 28 = 1008 square inches

If the rate is ₹35 per sq. inch →
1008 × 35 = ₹35,280 for that letter.

This technique is the correct and professional calculation method used in India.

Current Price Per Square Inch in India (2026)

Front Lit Channel Letters

₹ 28–₹ 45 per square inch

Backlit (Halo Lit)

₹ 40–₹ 65 per square inch

Combination Lit (Front + Back)

₹ 55 – ₹ 85 per square inch.

Trimless / Premium Finish

₹ 70 – ₹ 110 per square inch.

Rates vary depending on city (Delhi NCR, Mumbai, Bangalore and Tier 2 cities) material thickness and LED brand

What Determines the Per Square Inch Rate?

1. Aluminum Thickness

• 0.6mm (economy)
• 0.8mm (standard)
• 1mm+ (heavy duty for large letters)

2. Acrylic Brand

Imported cast acrylic costs more than local sheets.

3. LED Module Quality

Local LED = cheaper
Branded modules (better lumen & life) = higher rate

4. Letter Depth

A 3-inch depth vs. a 5-inch depth makes a difference in aluminum usage.

5. Finishing Quality

Powder coating, PU paint and CNC precision finishing affect the rate.

Installation Cost (Separate From Fabrication)

Many clients think per square inch includes installation. It usually does not.
Installation charges depend on the following:

• Mounting height
• Need of boom lift
• Structural support frame
• Electrical connection distance
• Site condition

Typical installation cost range:
₹ 10,000 – ₹ 75,000, depending on project size.

Practical Example (Indian Market Case Study)

Let’s say:

Brand Name: 8 Letters
Each letter approx size: 30" height × 24" width

Area per letter:
30 × 24 = 720 sq. inch

For 8 letters:
720 × 8 = 5760 sq. inch

If the rate is ₹38 per sq. inch (front-lit standard quality):

5760 × 38 = ₹218,880 fabrication cost
Installation is extra.

This is how professional signage vendors calculate pricing.

Why Large Letters Cost More Per Inch Sometimes?

For very large letters (above 3 ft in height):

• Reinforcement frame required
• Double LED layer sometimes used
• Heat ventilation needed
• More structural support

Hence, the rate per square inch may increase slightly.

Types of Large Channel Letter Styles

• Front Lit – Bright & economical
• Halo Lit – Premium glow effect
• Combination Lit – High-end branding
• Rooftop Letters – Heavy structural design

Common Mistakes While Comparing Rates

• Comparing a ₹25 per inch vendor with a ₹40 per inch vendor without checking aluminum thickness
• Not asking for the LED brand
• Ignoring installation height cost
• Not checking waterproof sealing

A lower rate today can mean repair expenses tomorrow.

Final Advice Before Finalizing Vendor

Always ask:

• Aluminum thickness?
• Acrylic brand?
• LED specification?
• Depth of letter?
• Installation included or separate?
• Warranty in writing?

Clear specification means clear costing.