A Complete Guide to Folded Tray Signs

Folded tray signs—also called sign trays—are a cornerstone of contemporary signage in the UK. These signs are known for their modern aesthetic, structural strength, and customisability. Whether you’re a retail brand, a property developer, or running a local café, a folded tray sign can elevate your visibility and solidify your identity.

Before we continue to the next section, would you like a brief overview of different types of sign trays or should we move straight into how they’re made and the materials involved?

How Folded Tray Signs Are Made

A sign tray is created by folding a flat sheet of material—typically aluminium or aluminium composite—into a tray-like shape. This process gives the sign structural integrity, clean edges, and a contemporary look that flat panels often lack. Here’s how it works in practice.

Material Selection

The most common material for folded tray signs is aluminium composite material (ACM). This is made by sandwiching a polyethylene core between two thin sheets of aluminium. It’s lightweight, rigid, weather-resistant, and easy to machine, making it ideal for outdoor business signs.

Alternatively, solid aluminium is used where extra strength or a more premium finish is required. It costs more but offers excellent durability and a sleek surface for finishing.

Other materials sometimes used:

• Steel – heavier, stronger, but prone to rust if not treated
  
• Acrylic – used more for internal trays or feature panels, not structural
  
• PVC Foamex – light and cheap, but not as robust for long-term use
  

The Folding Process

The “fold” in folded tray signs refers to the technique of bending the panel edges backward at 90 degrees to form a box shape. This is done using precision machinery like CNC routers and metal folders.

Key steps:

1. Panel is cut to size
   
2. Edges are V-grooved or scored
   
3. Edges are folded and fixed into place (with rivets, welds, or adhesive)
   
4. Fixing rails or return lips are added for mounting or stiffening
   
5. Face graphics are applied – printed vinyl, acrylic letters, fret-cut text, or illumination
   

The result is a seamless, box-edged sign that stands proud from the wall and looks smart from every angle.

Custom Sizes and Shapes

Because sign trays are cut from sheet materials, they can be made in virtually any:

• Size – from 300mm to 6m+ long
  
• Shape – rectangular, circular, oval, or fully bespoke
  
• Depth – usually between 25mm and 100mm depending on visibility and mounting
  

This flexibility makes tray signs especially popular for custom shop signage and commercial premises across the UK.

Why Choose a Sign Tray? Key Benefits for Your Business

Folded tray signs aren’t just about looks. They offer a range of functional, practical, and branding benefits that make them a smart investment for nearly any business. Here’s why they’re so widely used across the UK.

1. Professional, Polished Appearance

The seamless folds and clean edges of a sign tray give a much more premium appearance than a flat sign panel. There are no visible fixings on the face unless intentionally designed in, which helps maintain visual impact. The “box” effect subtly lifts the sign off the wall, giving it depth and dimension that flat boards can’t achieve.

This makes sign trays particularly suited for:

• Retail fascias
  
• Corporate offices
  
• Shopping centres
  
• Property development sites
  

2. Long-Term Durability

Sign trays are built to last. The aluminium composite or solid aluminium materials resist weathering, UV exposure, and corrosion. Whether exposed to sun, rain, wind, or pollution, a high-quality sign tray will maintain its appearance for years with minimal maintenance.

Even in high-traffic urban areas or coastal environments, sign trays stand up to the elements.

3. Versatility in Design

One of the strongest selling points of a sign tray is design flexibility. You can apply:

• Printed vinyl graphics
  
• Fret-cut (cut-out) lettering with illumination behind
  
• Raised 3D sign letters
  
• Acrylic or metal logo elements
  
• Halo lighting or internal LED modules
  

This flexibility allows brands to combine materials, textures, colours, and lighting for maximum visual effect. If your identity is bold, clean, or high-end, a folded tray sign will reflect that perfectly.

4. Hidden Fixings

A major advantage over traditional signage is that sign trays allow for hidden fixings. Instead of screwing through the face of a sign (which can weaken or cheapen it), the tray is mounted using internal brackets, Z-rails or rear studs.

This means:

• No screw heads or caps are visible
  
• The sign face stays perfectly flat
  
• Security is improved, as it’s harder to tamper with
  

5. Cost-Effective Branding

While sign trays offer a high-end appearance, they’re surprisingly cost-effective. ACM trays in particular strike a great balance between durability and affordability. For businesses looking to maximise visual impact without overspending, a sign tray offers exceptional return on investment.

You can also upgrade components (like using acrylic letters or built-in LED lighting) gradually without having to replace the full tray.

6. Scalable and Repeatable

If you operate multiple sites, folded tray signs are easy to replicate and roll out across locations. They’re CNC-cut to spec, which means you can maintain brand consistency across all premises. Ideal for franchises, estate agencies, restaurant chains and corporate offices.

Custom Design Options for Sign Trays

A folded tray sign is more than just a structural piece of signage. It’s a branding tool—one that can be tailored down to the smallest detail. Whether you’re aiming for minimal sophistication or something bold and eye-catching, sign trays offer an excellent canvas for customisation.

Face Finishes

The face of a sign tray can be finished in a range of materials and techniques depending on the visual effect you’re after:

Powder Coating

One of the most common finishes. It provides a smooth, durable, and UV-resistant surface in virtually any RAL colour. Ideal for businesses looking to match their exact brand palette.

Digital Print Vinyl

Printed vinyl graphics are applied to the tray face. These allow for:

• Full-colour logos
  
• High-resolution images
  
• Patterns or gradients
  

It’s cost-effective and great for complex or photographic branding.

Textured & Speciality Vinyls

Add a tactile feel or metallic sheen using specialty films such as:

• Brushed aluminium
  
• Matte black
  
• Carbon fibre
  
• Gold or copper effect
  

These are often used to highlight logos or sections of the tray for contrast.

Gloss or Matte Laminate

This seals the vinyl for extra protection and sets the tone—high gloss for sleek retail, matte for understated professionalism.

Graphic Techniques

A well-made sign tray combines fabrication with advanced graphics. Here are some popular options:

Flat Cut Lettering

Acrylic or metal letters are laser-cut and bonded to the face for depth. This creates a 3D look and allows colour contrast between the tray and the text.

Fret-Cut Detailing

Text or logos are cut out from the face of the tray itself, allowing light or a contrasting background to show through. Great for illuminated signs.

Push-Through Letters

Acrylic letters are pushed through fret-cut apertures and stand proud from the face. This adds depth and is ideal for halo or face-lit illumination.

Raised Logo Elements

Use foam, acrylic, or aluminium backing to lift logo elements off the tray, creating a multi-layered effect.

Lighting Integration

Lighting is a game-changer in signage—and sign trays handle it beautifully. See the next section for a detailed breakdown, but here’s a preview of what’s possible:

• LED backlighting
  
• Halo glow behind raised letters
  
• Edge-lit trays
  
• Illuminated push-throughs
  

Sign trays can be fabricated to house LED modules internally, giving you sleek, tamper-proof lighting that works day and night.

Edge Detailing and Returns

The sides of the tray (called returns) are visible from an angle, so they matter. Common custom options include:

• Contrasting colours for the edges vs. face
  
• Rounded vs. sharp corners
  
• Vinyl striping for visual breaks
  
• Wraparound designs for logos or brand patterns
  

The depth of the return also influences the visual presence. A 100mm return looks more substantial and architectural than a 25mm one.

Mounting Styles

You don’t have to mount a sign tray flat to a wall. You can also:

• Project it from the wall using stand-off brackets
  
• Suspend it using ceiling rods (great indoors)
  
• Flush-mount it for a clean, floating effect
  
• Use it as a back panel for other signage types
  

Lighting and Illumination Options for Sign Trays

Illumination transforms a sign tray from a static display into an all-day, all-night branding tool. It improves readability, adds drama and depth, and makes sure your signage is working even when your business is closed.

Here are the most effective lighting methods used with folded tray signs.

1. LED Backlighting

LED modules are installed behind fret-cut lettering or logo cut-outs on the tray’s face. Light shines through these areas, making the text or shapes glow against the otherwise opaque tray.

Best for:

• High-contrast night visibility
  
• Modern retail or corporate environments
  

Pros:

• Energy efficient
  
• Long lifespan (often 30,000+ hours)
  
• Low maintenance
  

2. Halo Lighting (Rear Illumination)

With halo lighting, raised letters or logos are mounted slightly off the tray face. LED lights are placed behind these elements, casting a subtle glow around their edges onto the tray surface.

Best for:

• Premium, elegant look
  
• Offices, salons, law firms, architects
  

Visual effect:
Soft, diffused glow around each element; understated but striking.

3. Face Illumination

In this setup, push-through acrylic letters are internally lit from behind, so the entire face of the letter glows. This can be combined with opaque borders for added clarity and edge contrast.

Common use cases:

• Hospitality
  
• Fast food chains
  
• Modern retail brands
  

Benefits:

• Excellent readability at night
  
• Strong brand presence
  

4. Edge-Lit Trays

Edge-lighting uses LED strips around the perimeter of the tray to create a glowing border effect. This method is often used with translucent face vinyl or frosted acrylic to soften the light and prevent glare.

Ideal for:

• Contemporary, minimal branding
  
• Signs with a futuristic or tech-oriented style
  

5. External Lighting (if internal isn’t possible)

When internal lighting isn’t an option—perhaps due to structural limitations—external downlighters or spotlights can be used. While less sleek, it’s still effective and easier to retrofit.

Tip: Combine external lighting with high-gloss finishes or reflective vinyls for better visibility.

Illumination Tips for Maximum Impact

• Choose the right colour temperature: Cool white for modern/clinical looks, warm white for boutique or heritage brands.
  
• Use opal acrylic for a softer glow. This prevents hot spots or patchy lighting.
  
• Test visibility in different conditions. A sign tray should look just as good in daylight as it does at night.
  
• Use quality LED modules. Cheap LEDs may fade, flicker or fail, damaging your brand’s first impression.
  

Mounting and Installation Methods for Sign Trays

Installing a sign tray involves more than simply attaching it to a wall. The method you choose affects aesthetics, structural integrity, maintenance access, and even lighting performance. Here’s what you need to know.

1. Face-Fix with Hidden Rails

The most common method. The sign tray is mounted using Z-section rails or aluminium angle brackets fixed to the rear of the tray and the wall.

Advantages:

• Clean, floating appearance
  
• No visible screws or caps
  
• Ideal for illuminated trays (space behind for wiring)
  

Installation steps:

• Rails are levelled and fixed to the wall
  
• The sign tray is slotted onto the rails
  
• Additional fixings may be used from inside the tray (not visible)
  

Best for:

Retail shops, restaurants, estate agents, corporate offices

2. Stud Fixing

This method uses metal studs or spacers mounted to the wall. The tray is drilled at precise points and slotted over the studs, which are either chemically bonded or anchored into the wall.

Pros:

• Sign stands off the wall slightly, improving depth
  
• Creates a shadow gap for a stylish look
  

Cons:

• Requires accurate alignment
  
• Not ideal for all substrates
  

3. Direct Wall Fixing (Screw-Through)

Sometimes used for smaller trays or cost-conscious projects. Screws go directly through the tray face and into the wall, often with plastic caps to hide them.

Downsides:

• Visible fixings can spoil the clean design
  
• Less secure
  
• Risk of water ingress if not sealed properly
  

Tip: Only use this method on low-impact or temporary installations.

4. Post-Mounted Sign Trays

For freestanding sign trays (such as outside a business park or petrol station), posts are used.

• Single or double post setups
  
• Sign tray is mounted via rails or a rear frame
  
• Ideal for drive-by visibility
  

Ensure posts are galvanised or powder-coated to resist corrosion.

5. Ceiling Suspension (Internal Use)

For indoor environments, trays can be suspended from ceilings using rods, cables, or wires.

Typical uses:

• Reception signs
  
• Wayfinding or department signage
  
• Hanging directional signs in shopping centres
  

Substrate Considerations

Different wall types need different fixings. Here’s a quick guide:

Surface	Recommended Fixing
Brick/Block	Wall plugs & screws or chemical anchors
Rendered walls	Longer fixings to go beyond render depth
Cladding	Secondary frame or through-fix with spacers
Glass or glazed areas	Use freestanding or suspended mounts
Interior drywall	Use wall anchors or fit to studs

Wiring for Illuminated Sign Trays

If your sign tray is illuminated:

• Ensure access to a mains connection or dedicated circuit
  
• Route wiring internally through the wall where possible
  
• Use waterproof grommets or cable glands
  
• Always comply with UK electrical regulations
  

Maintenance, Cleaning & Lifespan of Sign Trays

Even the most robust signage can lose its edge without proper upkeep. Understanding how to care for your folded tray sign will help extend its life, preserve its impact, and avoid costly replacements.

Typical Lifespan

With proper materials and installation, a sign tray can easily last 7–10 years or more. The longevity depends on several factors:

• Quality of materials (e.g. ACM vs. solid aluminium)
  
• Type of vinyls or coatings used
  
• Exposure to elements (sunlight, wind, coastal air)
  
• Illumination method (and quality of LED modules)
  
• Frequency of cleaning and inspections
  

A sign tray using UV-stable vinyl and premium LEDs could last well over a decade with minimal decline in performance.

Cleaning Guidelines

Regular cleaning keeps the sign looking professional and prevents long-term damage. Here’s how to do it right:

How Often to Clean

• Every 3–6 months for city centre or roadside signs
  
• Every 6–12 months for sheltered or rural locations
  

What to Use

• Soft microfibre cloths or sponges
  
• Mild detergent (pH neutral)
  
• Warm water (never hot or boiling)
  

What to Avoid

• Abrasive cleaners or cloths (they scratch finishes)
  
• Solvents like acetone or thinners (damage vinyl/paint)
  
• Pressure washers at close range
  

Common Maintenance Tasks

1. Check Fixings

• Every 6–12 months, inspect mounting points
  
• Tighten loose fixings or replace corroded hardware
  

2. Inspect Lighting

• Look for flickering or dim areas in illuminated trays
  
• Replace failed LED modules as needed
  
• Ensure waterproof seals are intact
  

3. Refresh Graphics

• Printed vinyl may fade after years of UV exposure
  
• Logos or text can be updated without replacing the tray
  
• Face wraps can be reapplied or changed for rebrands
  

4. Check for Panel Warping or Peeling

• Usually caused by poor-quality vinyl or extreme heat
  
• A sign tray in the UK climate is rarely at risk if made properly
  

Preventive Measures for Long-Term Performance

• Specify quality materials from the start – substandard ACM or cheap LEDs lead to early failure
  
• Use powder coating over spray paint – it resists fading and chipping
  
• Keep vegetation and drains clear near wall-mounted trays to avoid water pooling
  

When to Replace a Sign Tray

Even with good maintenance, there comes a time to replace. Indicators include:

• Irreversible damage (dents, corrosion, warped panels)
  
• Outdated branding or typography
  
• Faded graphics beyond reapplication
  
• Non-functional or obsolete lighting systems
  

Common Mistakes to Avoid with Sign Trays

Even though a sign tray is a relatively simple structure, getting it wrong can undermine your entire brand presence. From poor design decisions to bad installs, here are the key errors to avoid.

1. Choosing the Wrong Materials

Not all aluminium composite materials (ACM) are the same. Cheap ACM panels can warp, fade or delaminate over time, especially in full sun or wet environments.

Avoid:

• Thin, budget-grade ACM (usually 2mm or less)
  
• Non-UV-stable vinyls or paint
  
• Low-grade LED modules with short life expectancy
  

Do:

• Specify premium 3mm ACM or solid aluminium for high-end installs
  
• Use vinyls designed for outdoor, long-term use (e.g. Avery Dennison, 3M)
  
• Confirm LED ratings and warranty from the supplier
  

2. Ignoring Illumination Needs

Some businesses add lighting as an afterthought, resulting in poorly integrated or messy LED installs.

Don’t:

• Rely on external lighting if the design requires backlighting
  
• Add LEDs without proper ventilation or waterproofing
  

Instead:

• Decide early if your sign tray needs internal lighting
  
• Build the tray with LED modules and power routing in mind
  

3. Overcrowded Design

Cramming too much text or using overly decorative fonts can make your tray hard to read—especially from a distance.

Avoid:

• Small text sizes
  
• Low-contrast colour schemes
  
• Complex or script fonts for main messaging
  

Do:

• Stick to one or two fonts max
  
• Use high-contrast colour combinations
  
• Prioritise legibility over ornamentation
  

4. Poor Sizing and Positioning

Too-small sign trays get lost on large façades, while oversized signs can overwhelm or look unbalanced.

Check:

• The viewing distance and angle from nearby roads/pavements
  
• The visual scale relative to your building
  
• Local planning permission rules (especially in conservation areas)
  

5. DIY or Unqualified Installation

Sign trays may look simple—but poor installation leads to:

• Crooked alignment
  
• Water ingress
  
• Damaged façades
  
• Safety risks (especially with heavy trays or lighting)
  

Solution:
Always use professional installers with experience fitting tray signs in the UK. Ensure they’re insured and follow safety and electrical standards.

6. Not Planning for Future Access

Trays without removable panels make lighting or wiring maintenance a headache later on.

Frequently Asked Questions

What is a sign tray?

A sign tray is a folded panel—typically made from aluminium or aluminium composite—that forms a rigid, box-like structure. It’s mounted to a building façade and used as a base for graphics, logos, or illuminated signage. The folded edges (returns) give the sign strength, depth, and a clean finish.

What’s the difference between a sign tray and a flat panel sign?

Unlike flat panels, a sign tray has folded edges, which provide both structural integrity and visual depth. Sign trays look more premium, hide fixings, and allow for built-in lighting. Flat signs are cheaper but can look less polished and may not last as long.

Are sign trays suitable for outdoor use?

Yes, sign trays are designed for outdoor use and are widely used across the UK on shopfronts, offices, and business parks. Made from weather-resistant materials like aluminium composite, a well-installed folded tray sign can withstand rain, wind, UV rays, and pollution for years.

Can I illuminate a sign tray?

Absolutely. A sign tray is ideal for illumination. You can backlight cut-out text, push-through letters, or install internal LED modules. Sign trays are often fabricated with space and access for lighting integration. Just ensure proper planning and waterproofing for outdoor installations.

What size can a sign tray be?

There are no strict size limits. A sign tray can range from under a metre to over six metres in width. Common depths (returns) include 25mm, 50mm, and 100mm. Oversized trays are typically manufactured in sections and joined seamlessly on site.

How is a sign tray installed?

Most sign trays are installed using:

• Z rails (for clean, flush mounting)
  
• Stud fixings (for stand-off mounting)
  
• Wall brackets or post supports (for freestanding applications)
  

Lighting trays may also require internal wiring access. Always use professional installers to ensure alignment, safety, and longevity.

Can a sign tray be customised to my brand colours?

Yes. A sign tray can be:

• Powder-coated to any RAL or Pantone colour
  
• Wrapped in printed vinyl with logos and graphics
  
• Detailed with contrasting returns, 3D letters or light effects
  

This flexibility makes sign trays the ideal choice for consistent, branded signage.

How much does a sign tray cost in the UK?

Prices vary depending on:

• Size and material (ACM vs. aluminium)
  
• Graphics complexity
  
• Illumination (LED integration)
  
• Installation location
  
  

Get a custom quote for accurate pricing based on your needs.

How long does a sign tray last?

A well-made sign tray can last 7–10 years or longer with minimal maintenance. LED components may require replacement after 5–8 years, depending on usage. Using premium-grade vinyls and UV-resistant materials will greatly extend life expectancy.

What finishes are available for sign trays?

Your sign tray can be finished in:

• Matte, satin or gloss powder coating
  
• Brushed or polished metal films
  
• Printed full-colour vinyl wraps
  
• Special textures like carbon fibre, woodgrain, or chrome
  

You can also mix finishes—for example, a matte black tray with gloss acrylic letters—for added visual impact.

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Can I update graphics on an existing sign tray?

Yes. A major advantage of a sign tray is that the face graphics can be updated without replacing the entire tray. Vinyls can be removed and replaced with new branding. If lighting or structure remains intact, this makes rebranding cost-effective.

Do I need planning permission for a sign tray?

Possibly. In the UK, you may need planning consent if:

• The tray is illuminated
  
• It’s in a conservation area
  
• It’s over a certain size or projects from the wall
  

Always check with your local planning authority or consult a signage professional before installation.

Are sign trays environmentally friendly?

Aluminium and ACM used in sign trays are recyclable, and modern manufacturing often reduces waste. LED lighting also consumes less power and has a lower environmental impact than older systems. Opt for suppliers that use sustainable materials where possible.

Can I install a sign tray myself?

It’s not recommended. A sign tray must be level, secure, and weatherproof. For illuminated trays, electrical work must be done to UK standards. Incorrect installation can lead to water damage, electrical faults, or structural risk.

Always use a qualified signage installer with relevant experience.