Cutting the retroreflective sheets
4 Using scissors, razor blades, a knife, or a paper cutter, individual background retroreflective sheets are cut by hand. Multiple sheets, on the other hand, are cut using a band saw. In this process, the shape of the sign is traced on to a 0.125-inch (3.2 mm) wallboard. This wallboard is laid on top of about 50 sheets, secured and nailed to a hardboard cutting base. The band saw follows the pattern and cuts the sheets.
5 Letters and symbols are punched out from white or black retroreflective sheeting either by hand or by using a "clicker" press. Up to 29 sheets can be placed in the press at once; cutting dies, which function much like cookie-dough cutters, are placed in the machine to produce the desired characters.