The Process

Enameling is an old and widely-adopted technology. The ancient Egyptians applies enamels to pottery and stone objects. Other pioneers include the ancient Greeks, Celts Russians and the Chinese. Ancient porcelain enameled art objects are perfectly preserved in many museums and art collections around the world.

Porcelain enamel has many excellent properties. It is smooth, hard, chemically resistant, durable, long lasting, brilliantly colored and cannot burn. Porcelain creates an ideal surface for the adhesion of unique and durable images. The enameled shell is inherently flint hard but maintains a finish as smooth as glass. Porcelain is created by the fusion of mineral components using intense heat. This creation will never changes its texture or chemical content merely due to wear. Because of this, art images or designs can be screen-printed on the enameled steel and hardened, creating a finished product that resists fading or loss of luster. In fact, the enameled signs are just as brilliant and lustrous in the - 40° below weather of Alaska as it is in the sun-baked and salt-laden air of the Gulf Coast.

Production

Large sheets of special enameling steel are delivered from the mill to our factory. We begin fabrication by sheering the large sheets into individual signs. Mounting holes are punched and corners are rounded. Intricate shapes can be formed using stamping dies or laser-cutting techniques. The steel then goes through a series of cleaning baths to prepare for coating. The first "ground coat" is applied and run though our furnace at 1470°F. This application is specially formulated to bond the porcelain to the steel. The steel is then given a second coating, a white "cover coat", and again run on a conveyor through our furnace. After cooling, these plates are ready for the application of artwork.

Unlike most paints, porcelain enamel color pastes are composed of inorganic minerals (capable of withstanding the intense heat). This is what gives porcelain signs their incredible durability. the colors are applied to the sign using the silk-screen process. Each individual color requires its own screening. A five color sign requires 5 screenings. Each time a color is screened, the enamel must dry before the next color is applied. When all the colors are applied, the sign is run through our furnace for a final firing. Now that the plates are nearly complete, the image is inspected and the mounting holes are then fitted with eyelet. The final product is glossy, vibrant and incredibly durable.

Restrictions and Limitations of our Porcelain Signs:

• The largest size we can produce is 30" x 36"
• We do not color match, but offer a large variety of colors to choose from.
  Samples are available, but must be returned or there will be a $50 charge.
• All signs are screen printed.
• Artwork must be vector, color seperated or supplied on film.
• Please RFQ with information about quantity, size, number of colors, hole size and location and include
  a pdf/jpg of the artwork.