How to create a 4D 3mm with gel or 'crystal' with gel number plate

Intro

Sometimes, customers can't decide between 3D gel and 4D laser cut number plates. They like them both, so it's a difficult choice to make! That's where 4D 3mm with gel, or crystal with gel comes into play. The customer can have the best of both worlds; the sharp edges and depth of the 4D letters, combined with the curved light catching 3D gel.

Step by step:

1. Taking the acrylic and reflective that you produced following our previous guide (see here if you've not done this step yet), place it securely into your purpose built number plate jig.
2. Gather the letters and digits required for the registration you're making; starting with the 4D crystal or black, and then the gel to go on top. Don't forget to double these if you are producing both a front and rear plate.
3. Looking at the guidance on the top of your jig, match the registration format to the registration you are producing. For example, UP14 TES would use number 2, matching XX10 XXX. This will be your starting point.
4. Position the slider so that the left side is directly on the line below the relevant number (2 in our example). Peel off the protective film from the rear of the 4D character and place it carefully onto the plate through the open section of the slider. Ensure you place it correctly, using the bottom of the slider to align the character. Once you're sure of it's position, press down with a bit of pressure. Leave the protective film on the 4D character for now.
5. Lift the slider off the jig and reposition it on the right of the character you just placed, placing the left side of the slider firmly against the first character. Place the next character in the open section, just as you did on the first character.
6. Repeat the process for each character as necessary. When you come to the point where you need a larger space (33mm as opposed to standard 11mm), use the extra spacing bar to increase the gap. This would be between the 4 and T in our example registration. Continue as normal after you have made this larger space.
7. Upon placing the final character onto the plate, remove it from the jig and hold it up. You should inspect the plate carefully to ensure characters are consistent in their vertical positioning, forming a neat line, and ensure there are no other notable issues.
8. If there are any issues with the placement of the characters, you can attempt to remove individual characters by bending the number plate where the incorrect character is, then prying up the digit. This will be extremely difficult, and nigh on impossible with our 4D 5mm characters.
9. If you are pleased with the result of the first plate, and the customer has requested a pair of plates, produce the second number plate following the same strategy.
10. When you have finished both plates, or the single plate if the customer has not requested a pair, you should apply extra pressure to the letters and numbers to ensure that the pressure sensitive adhesive is fully activated. If you have a height adjustable roller, set this to the optimal height for the plate and letter combination, and roll them through. There should be plenty of resistance as you roll them.
11. Now that you have a set of 4D 3mm or just 4D crystal plates, it's time to add the gel. Peel the front protective layer from each of the 4D characters, be they 3mm or crystal. Once you have removed all of the protective film from the characters, you can begin placing the gel letters on top. Peel the gel letters from their wax paper backing.
12. Use two hands when placing the gel letters on top of the 4D characters, so you may ensure that they are positioned as best as possible. You want each edge to have a uniform space between the gel and 4D character. There will be a slight overlap on the gel, as they are a tiny bit larger than the 4D characters.
13. Once you have applied all of the gel characters, it is advisable to use some pressure to ensure they're stuck down - place one number completed number plate on your work bench, with the letters facing up. Place the second number plate on top, with the characters facing down so they press against the first plate. Use your body weight to add some pressure to the back of the top number plate. If you have only made a single plate, use your palms to press down against the gel on the single plate.

Important notes:

• The 3D gel letters could do with a polish, as with a normal 3D gel number plate. However, now that they are raised from the plate with the 4D/crystal characters below, you should spray your polish directly onto the microfibre cloth and then wipe down the letters. If you spray directly onto the number plate, the spray will go between the letters making it difficult to clean up fully before handover to the customer
• Don't forget to use pressure on the 4D/crystal plates before you add the gel on. This will ensure the 4D characters stay strongly attached.
• If you don't have a height adjustable roller, you can apply pressure to the characters in alternative methods, some more unorthodox than others. You can, for example, place the number plates on the floor (ideally protected by a microfibre cloth) and then stand upon them. Distribute your weight across the plate to ensure all characters are affected.