How do you remake the pattern? Seems like a good deal of extra work compared to just lining with tape, but if they are sending you digital patterns, that's a whole different story.
Fun story, we had direct
sign wholesale make some letters for a
sign in 2010. Earlier this year we got the job to do new plastic faces and replace the LED's. We gave them a call to see, and they had the files for the faces archived, so instead of the old trace and jigsaw gig, we just cut new faces on the router. Cut the time down from several hours to maybe 1. Moral of the story, reach out to your wholesalers for anything you know that you got from them. Chances are, they never deleted that 1.44MB worth of data...