Generating channel letters using profiles

1. A method of forming a channel letter box using a profile, the method comprising:

determining an incision position on one surface of the profile where at least one surface incision is to be made, the one surface of the profile having at least one protruding rib oriented along a longitudinal axis of the profile;

surface incising at the determined incision position to create the surface incision substantially transverse to the at least one protruding rib;

folding the profile at the incision position to form the channel letter box; and

cutting and attaching a top plate to the channel letter box, the top plate having a thickness substantially close to a distance from a top of the profile to a top of a top protruding rib of the at least one protruding rib.

2. The method of claim 1 , further comprising

attaching the channel letter box to a base plate.

3. The method of claim 2 , wherein attaching the channel letter box to a base plate comprises

inserting a bottom protruding rib of the at least one protruding rib into an open slot of a clip which is fixed to a flat surface by a screw.

4. The method of claim 1 , wherein surface incising comprises

forming a ridge at the incision position on the one surface of the profile to make an effective thickness of the profile at the incision position to measure between 0.2 and 1.5 millimeters.

5. The method of claim 1 , wherein the incision position comprises at least one line.

6. The method of claim 1 , wherein a number of lines in the incision position is determined by a desired curvature of the fold at the incision position.

7. The method of claim 1 , wherein surface incising comprises

making a cut along the incision position,

wherein the cut is made in the at least one protruding rib and partially into the one surface of the profile.

8. The method of claim 1 , wherein cutting and attaching a top plate to the channel letter box comprises

attaching the top plate to the top protruding rib of the channel letter box using attaching material including a clip.

9. A method of forming a channel letter box using a profile, the method comprising:

determining an incision position and an incision depth on one surface of the profile where at least one surface incision is to be made, the one surface having at least one protruding rib extending along a longitudinal axis of the profile;

surface incising at the determined position and for the incision depth using a sawing unit, the sawing unit configured to make a v-cut into the at least one protruding rib and the one surface of the profile in a direction substantially transverse to the at least one protruding rib;

folding the profile at the incision position using a folding unit to form the channel letter box; and

cutting and attaching a top plate to the channel letter box, the top plate having

a thickness substantially close to a distance from a top of the profile to a top of a top protruding rib of the at least one protruding rib.

10. The method of claim 9 , wherein the incision position comprises at least one line.

11. The method of claim 9 , wherein a number of lines in the incision position is determined by a desired curvature of the fold at the incision position.

12. The method of claim 9 , wherein surface incising comprises

making a cut along the incision position,

wherein the cut is made in the at least one protruding rib and partially into the one surface of the profile.

13. The method of claim 9 , wherein surface incising comprises

using the sawing unit to make a v-cut at the incision position on the one surface of the profile to make an effective thickness of the profile at the incision position to measure between 0.2 and 1.5 millimeters.

14. The method of claim 9 , wherein cutting and attaching a top plate to the channel letter box comprises

attaching the top plate to the top protruding rib of the channel letter box using attaching material including a clip.