Those letters look like they are vacuum thermoformed. Have to make a mold out of wood or epoxy with strategically located vacuum sites to suck the heated plastic sheet to. After the sheet cools down then the letters need to be cut out with a cutting die made special for the letters. It’s not a difficult process but hard to do economically for one or two sets!

Process used a lot for packaging trays. I’d look for a packaging company near you that doesn’t mind doing small quantities. They’ll probably say no thanks though.


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