How It’s Made

I wanted to take a moment to explain the process behind creating our incredible metal art signs.

It all begins when a customer makes a purchase on one of our websites, either HDSignworks or through our Etsy store. Once the order is placed, the sign design is customized using a CAD program to meet the customer's specifications. After this, we send a confirmation email with a preview of the design.

Next, the design is transferred into a Numerical Control (NC) program to generate a cutting path. The design is then imported into our CNC Main Control System, where the sign is precisely cut from a sheet of metal.

Once cut, the sign goes through a large belt sander to remove any dross from the back and to smooth both sides. If the sign requires rusting or a color other than black, it is further sanded with a finer grit for a smoother finish.

After sanding, the sign is thoroughly washed and dried. It undergoes a meticulous quality control check for any imperfections. If it passes, the sign is prepped for powder coating. During this stage, an electrostatically charged powder is applied, and the sign is baked in a large oven at 400 degrees Fahrenheit for about 10 minutes. Once finished, it is packaged and ready for shipment.

For rusted signs, after the initial washing, the back of the sign is painted in flat black to protect surfaces from discoloration when hung. After drying for a day, a chemical agent is applied to the front, which triggers the rusting process. We allow the rust to develop naturally over a couple of days, etching it into the metal for an authentic aged look. The sign is then wiped down, packaged, and shipped. We do not artificially speed up the rusting process, ensuring a genuine weathered appearance.

I hope this blog gives you some insight into the craftsmanship and care that goes into making our metal art.