We originally planned the Hearth Park hand-routed sign to be a hand-carved sign. However, because of its 30″ x 72″ dimensions, and the depth of the square-cut, recessed letters, we decided that hand-routing would enhance the sign’s overall texture and the precision of its recessed letters. Also, using a router would speed up turn-around time.

Materials, technique and finish

Usually, the two best substrates for sandblasting, hand-carving or hand-routing signs are wood and high-density urethane (HDU). Of the two, HDU is usually the most cost-effective. In addition, HDU has the weight of wood, but none of wood’s irregularities. It is extremely high-density foam that responds well to all types of carving and shaping. HDU is a popular choice for highly-shaped signs that involve dimension. In fact, those colorful 3-D signs we see in theme parks like Disneyland are oftentimes carved HDU.

A word about wood…

On the other hand, wood is, well, wood. It has natural irregularities that can make it a challenge to work with. Unless it’s seasoned (aged), it can warp and become unattractive, ruining the hard work of preparing, carving and finishing it. It’s also more expensive. Naturally, the larger the sign, the higher the cost. So, we prefer to use HDU because we can achieve wood’s texture and appearance by using unique tools and clever faux techniques. Most importantly, we can save our clients added expense.

The Hearth Park sign also has matching routed and painted posts (see above photo). The deep, rich, complementary chocolate background and blue and white highlights are effective and pleasing combinations. Sign design provided by the client.

Call us for your routed or hand-crafted sign at, 970-221-5519

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