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...THE DESIGN FACTORY


SIGNS
WITHOUT STRUCTURES

hand carved, incised, routed, sandblasted and cut out letters
See signs with structures
Designers and Makers of Quality Handcrafted Custom Wood Signs and Other Custom Woodwork


KEN KAIYALA
Spokane Washington
509 255-5355
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©The Design Factory 2006-2009
site and products
The Design Factory has been designing and crafting hand carved, routered and sandblasted wood signs for 24 years.  They have been made for subdivision entrances; restaurants; business; apartment and condo complexes; resorts; parks; ranches; highway rest stops; lake cabins and as decorative items. The Design Factory's clients have included city, county and state governments as well as private businesses.


Technical Info Below:
Wood Used
Mixed Media
Post Materials
Structures
Finishes

Wood Used
Clearheart vettical grain laminated western red cedar or genuine mahogany is used for almost all signs.

Mixed Media Signs
Mixed-media signs can have accents or mounting structures made from metal, stone, wood urethane foam or othet high density materials

Post Materials
Posts for signs are either pressure treated fir, hemlock, western cedar or steel depending on the design or client specifications.

Structures
Concrete pads, footings and masonary structures are the responsibility of the client. However, The Design Factory can arrange for a sub- contractor.
INSTALLATION, DELIVERY & KITS
Our extensive wood and metal working backgrounds give us the ability to design, make and install complete sign mounting structures as well as the signs themselves.  If you need a sign outside of the Spokane area sign packages are available as KITS complete with easy to understand instructions. Ken Kaiyala brings his manufacturing engineering experience and education as well as his work in all phases of construction to the manufacturing process. This in turn allows us to ship signs anywhere with confidence.  We have successfully shipped signs to Washington, Idaho, Oregon and Hawaii.
  




  • The sign is made from 3'4" pine, Mdo plywood and high density urethane foam.
  • The frame and panel were assembled and decorated with a 3/8" bead moulding. The copy was cut out, sculpted and applied.
  • The sign was designed from existing logo elements a produced by The Design Factory
  • 24" X 28"


  • The sign blank is 1 3/4" laminated clear heart, vertical grain western
    red cedar.
  • The egret and large copy are cut from high density uretane foam cut out, sculpted and applied.
  • It is finished with artist's acrylic paints.
  • The small copy is routered into the sign face.
  • The sign was designed and built by The Design Factory
  • 30" long oval.




  • The sign is made up of 6 layers of clear heart vertical grain western red cedar and finished with artist's acrylic paints.  Custom mounting polished steel pins with shaped clamps were designed and manufactured to clamp onto the roof rack of a Land Rover.
  • The double sided sign is made up of cut out, sculpted and carved pieces with hand carved and routered copy.  The vehicle was cut out, carved, painted and applied.  All sign edges are hand hewn and backgrounds are textured.
  • The Design Factory designed this sign and components based of an illustration in a Land Rover advertising piece.
  • 20" high and 60" long, 4 3/4" thick.
     




  •  The sign blank is medium density overlay plywood cut to shape.
  •  The border is made from 2" thick high density urethane foam cut out, glued to the MDO and carved and sanded to shape.
  • The letters are cut out of 2" thick high density urethane foam, shaped and glued in place.
  • The border and letters are painted with metallic gold paint.
  • The background is dark green glass smaltz glued to the MDO.
  • The finished sign is mounted to the building on a custom made aluminum frame.
  •  The Design Factory designed and manufactured all elements of this sign.
  • 3" thick x 54" high x 120" long restaurant sign:







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Home....Signs with Structures.....Signs without Structures.....Landscape Structures....Kitchen Furniture & Bread Boards
Doors....Awards....Liturgical Art & Church Furniture...About Ken Kaiyala....How to Order.....Email