Need Help what dimensional lettering material to use?

Fabricated aluminum, They can be made any thickness. They are lightweight because they are hollow.
It's like a reverse channel letter but without the neon.
I have them made here locally, but I would think Gemini would be my first try

 

You're really limiting yourself by requiring a gloss edge.

Considering it's going inside, I'll go with Trupan/Ultraboard. If you prep it right, you can paint it to look as good or better than acrylic. A 4x8x12mm sheet is about 25-30 lbs I believe. Acrylic is about 90lbs I believe. Trupan is also 10% of the cost.

 

I would use 1/2" pvc. Once routed you will have the thickness you want and it wont be heavy nor very expensive. you will not have that gloss edge though. Acrylic is going to be expensive but that might be the way to go. fabricated aluminum will be best bet BUT you are going to pay out the *** for that....let me guess some dumba$$ architect or interior designer came up with the gloss edging?

 

That's a hard one. do they really have to stand off .5"? Can you talk them into flush mount? If not, maybe go with clear flame polished with black faces so that you can flush stud mount them.

 

Sounds like a Gemini job to me. Molded plastic letters - lightweight and glossy, stud mountable.

 

Have done the same size letters with HDU that gave a gloss edge and hung with only 6 or 8 pins depending on letter