The process of creating channel letters typically involves the following steps:

1. Design: The first step in creating aluminum letters is to design the sign or display. This can be done using graphic design software or by hand.

2. Material selection: Once the design is finalized, the next step is to select the appropriate type and thickness of aluminum. Aluminum sheets come in a range of thicknesses and finishes, so it’s important to choose the right material to achieve the desired look.

3. Cutting: There are several methods for cutting aluminum, including laser cutting, water jet cutting, and CNC routing. Laser cutting is a popular option for creating precise and intricate designs, while water jet cutting is often used for thicker materials or for creating more complex shapes. CNC routing is a more traditional method that can be used for simpler designs.

4. Bending: Once the aluminum letters are cut, they may need to be bent or formed into the desired shape. This can be done using a bending brake or other specialized tools.

5. Finishing: Once the aluminum letters are shaped, they may need to be sanded, polished, or anodized to achieve the desired finish. Anodizing is a process that adds a protective layer to the aluminum, making it more resistant to weather and corrosion.

6. Assembly: Depending on the design, the aluminum letters may need to be assembled into a larger sign or display. This can involve attaching the letters to a backing board or mounting them directly onto a surface.

7. Lighting: If the aluminum letters are being used for illuminated signs or displays, lighting elements such as LEDs may need to be added.