If you produce photopolymer ADA signage, you already know the stakes. A sign that fails in the field is not just a quality issue. It is a compliance issue, a liability issue, and a direct hit to your reputation as a fabricator. The good news is that when you follow the Nova Polymers’ sign manufacturing system correctly, field failures become rare exceptions rather than recurring headaches.
This guide breaks down how the system works, where fabricators commonly go wrong, and why sticking to the process is the most reliable path to producing 100% ADA-compliant signs your clients can count on for years.
What Is the Nova Polymers' Sign Manufacturing System?
The Nova Polymers’ sign manufacturing system is an end-to-end approach to photopolymer sign fabrication that combines substrates, processing equipment, design software, and production guidelines into one cohesive workflow. Rather than sourcing materials from one vendor and equipment from another, fabricators work within a single-source framework designed to eliminate the guesswork that leads to compliance failures.
At the core of the system are Novacryl photopolymer substrates, available in a range of formulations to meet different project requirements. From the standard PT Series for interior signs to the EX Series for exterior and high-humidity environments, each substrate is engineered to work within Nova’s processing equipment. The system also includes the WorkFlow Manager software, which reduces the risk of design errors before a single sheet is exposed.
The Five Processing Steps and Why Each One Matters
Processing Novacryl material involves five sequential steps. Skipping or rushing any one of them is the most common source of field failures.
Step 1: Film Negative PlacementÂ
A high-density film negative is placed directly on top of the photopolymer sheet. Any air gaps between the negative and the substrate will cause the UV light to scatter, resulting in poorly defined character edges. Braille domes and raised copy that appear sharp on the bench may fail dimensional compliance checks after the sign is installed.
Step 2: UV Exposure (Front)Â
A bank of UV lamps exposes the material through the clear areas of the film negative, curing the photopolymer in those zones. Exposure time is not a suggestion. Under-exposure leaves the sign soft and vulnerable to damage. Over-exposure can close up fine details and cause Braille domes to fuse together, which is a direct ADA compliance failure.
Step 3: WashoutÂ
The unexposed photopolymer is washed away in plain tap water. This step reveals your raised characters, Braille, and pictograms. Water temperature, wash duration, and brush pressure all affect the outcome. Inconsistent washout is one of the top reasons fabricators see flat or malformed Braille cells on finished signs.
Step 4: DryingÂ
The sign must dry fully and evenly before the second UV exposure. Rushing this step traps moisture beneath the surface layer, which can cause adhesion problems with paint or digital print finishes later in production.
Step 5: Post-Exposure (Back)Â
The final UV exposure cures the entire sign from the back side, hardening the base layer and locking in the raised elements. Skipping or shortening this step is a silent failure mode. The sign may look perfect on delivery, only to see Braille domes soften or separate under repeated tactile contact in the field.
Choosing the Right Novacryl Substrate for the Application
One of the most preventable causes of field failures is using an interior-grade substrate in an exterior or high-humidity environment. The Nova Polymers’ sign manufacturing system addresses this with purpose-built substrate lines.
The PT Series is the most versatile interior line. It is shatterproof, contains 40% post-industrial recycled content, and can be painted or digitally printed, giving fabricators significant creative flexibility. The AC Series uses an acrylic base that reduces production costs while still meeting full ADA compliance requirements. The EX Series is the only pure exterior-grade photopolymer on the market, engineered specifically for moisture, humidity, and temperature variation in locations like parking garages, stairwells, and outdoor building entries. For emergency egress applications, Permaglow provides photoluminescent performance alongside compliant raised Braille that resists vandalism. The AL Series adds an aluminum-backed option for classic or art deco aesthetics.
Matching the substrate to the environment before production begins is a basic quality control step that too many fabricators overlook until a client calls with a warranty issue.
How the WorkFlow Manager Reduces Human Error
Design errors are a quiet contributor to ADA compliance failures. Incorrect character height, improper Grade 2 Braille translation, and spacing that falls outside the 2010 ADA Standards are all errors that are easy to miss in a busy shop and difficult to correct after installation. Nova’s WorkFlow Manager software builds compliance checks into the design stage, flagging problems before they reach the processor. Less rework, less material waste, and more consistent output across your production runs.
Frequently Asked Questions
Q: How do I know if my Novacryl processing times are correct? Nova provides detailed Novacryl Processing Guidelines that specify exact exposure times, washout durations, and drying parameters for each substrate line. Always reference the guidelines for the specific product you are running, as times vary between substrate series.
Q: Can photopolymer signs be used outdoors? Interior-grade substrates like the PT and AC Series are not designed for outdoor exposure. For exterior applications, the EX Series is the correct choice. It is formulated to withstand moisture, humidity, and environmental stress that would degrade a standard interior substrate.
Q: What causes flat or malformed Braille domes? The most common causes are insufficient front-side UV exposure, improper washout technique, or using a degraded film negative. Each of these variables is addressed directly in the Novacryl Processing Guidelines. If you are seeing Braille quality issues, reviewing your exposure and washout settings against the guidelines should be your first step.
Q: Does Nova offer training for fabricators? Yes. Nova Polymers offers training resources and a free ADA webinar series. This includes support on processing procedures, ADA specifications, and equipment operation. Access to processing guidelines, SOPs, troubleshooting guides, and SDS sheets is also available through their website.
Q: What happens if signs fail ADA compliance after installation? Non-compliant signage exposes building owners to ADA enforcement complaints and legal liability. As the fabricator, compliance failures can also result in charge-backs, costly replacements, and damage to client relationships. Following the Nova Polymers’ sign manufacturing system, as designed, is the most direct way to protect yourself and your clients.
Ready to Tighten Up Your Production Process?
The Nova Polymers’ sign manufacturing system exists to take the uncertainty out of ADA photopolymer sign fabrication. Whether you are troubleshooting an existing quality issue or building out a more consistent production workflow, the resources are available to help you get there. The Nova Polymers’ team is here to help support you. Contact us for more information.
