Sign / Panel Size

Recommendation is based on the longest single dimension (width or height), since that's what governs handling, seams, and wind flex.
Recommended Face Material —

Size Relative to Switch Points

Acrylic
Polycarbonate
Flex Face
0'

Specific Product / Grade

Reference — All Material Codes

MaterialProductNotes
Acrylic (LED-lit)White 244747–55% light transmission, brightest, standard for LED channel letters/cabinets
Acrylic (fluorescent-lit)White 732828–32% light transmission, decades-long "sign white" standard, best diffusion/no hot spots
Acrylic (non-illuminated)White 7508Opaque bright white
PolycarbonateLexan / Palsun / Makrolon (UV-stabilized grade)~30x more impact resistant than acrylic; yellows over time, faster in high-sun climates — spec UV-stabilized, not GP grade
Flex Face18–20oz vinyl (Duraflex, Verseidag, Sefar, etc.)Avoids seams on large cabinets; can't do routed/dimensional faces
Reference estimate only — synthesized from sign-industry trade sources and fabricator forum consensus (Piedmont Plastics, Federal Heath, signs101.com). Published size thresholds vary by source; treat the numbers on the Thresholds tab as a tunable starting point for Flite's own practice, not a hard engineering limit. High-wind/coastal jobs should still be checked against local wind load code.