This is the low tech design method that I used for the test sign as well as for the first group of seven signs:

– Use exisiting MS Excel sign layout drawing
– Finalize in MS Word to get a better border
– Convert to .pdf
– Use Zamzar Conversion to make it a .jpg
– Use Shapeways 2D to 3D to make the model
– Submit model
– Hope
– Get printability report
– Back to square one or two for some
– Order a 3D ‘print’ of the survivors
— (In the cheapest practical material)
– White, Strong and Flexible was ‘On Sale”!
— It is a sintered white nylon
– Got three signs from the seven submitted
– This one for the Town Hall was one of three that were ‘printable’

Painting the sign:
– Primed with Tamiya Fine Surface Primer Item 87064
– Painted the front in my desired non-white background color
— Tamiya Black TS-14 for the sign below
– Flat sanded the raised letters and frame with 400, then 600 grit
– Voila’ – intended to produce a sign with a black background and white letters
– Sprayed it with Krylon UV Resistant Clear Matte Acrylic

Results
– The material is a sintered nylon and is extremely porous
– Note that the black paint soaked into the white sign
— The crossbar in the ‘H’ shows the black, for example
– The long term effect of outdoor exposure is looking good
— Outdoor testing started August 22, 2013 as shown above and below
— December 14, 2019 Report – Several Central Indiana very cold winters and very hot summers and still no sign of deterioration