Cutting, Sealing & Custom Shaping EL Panels

Introduction

Standard EL panels can be cut to custom shapes, allowing you to create unique designs tailored to your specific needs. However, cutting requires careful technique and proper sealing to ensure safe operation and panel longevity.

This guide covers cutting techniques, sealing methods, and the decision between DIY cutting and ordering pre-cut custom panels from Ellumiglow.

Tools Required

Before you begin, gather these tools and materials:

Cutting Tools

• Sharp Utility Knife: A fresh, sharp blade is essential for clean cuts. Dull blades tear the material and create ragged edges that are hard to seal
• Precision Scissors: For smaller curves or detailed work, high-quality scissors can be easier to control than a knife
• Metal Ruler or Straightedge: For guided cuts and accurate measurements

Sealing & Protection

• Clear Nail Polish: For quick, temporary edge sealing
• 2-Part Epoxy Resin: For permanent, durable sealing (5-minute or 24-hour cure, depending on your timeline)
• Heat Shrink Tubing: Optional, for protecting connections and edges
• Conformal Coating: Professional-grade waterproofing (optional)

Assembly & Inspection

• Crimp Connectors: For making reliable electrical connections
• Soldering Iron: For soldering connections after crimping
• Multimeter: For testing continuity and electrical integrity
• Clean Cloth or Lint-Free Paper: For cleaning cut edges before sealing

Cutting Technique

Preparation

1. Measure and mark your cut lines clearly using a ruler and pencil
2. Place the panel on a clean, flat work surface with adequate space
3. Use a metal straightedge to guide your blade for straight cuts
4. Ensure the panel is fully supported and won't move during cutting

The Cutting Motion

Use a single, clean cutting motion rather than multiple passes. Sawing back and forth tears the material and creates rough edges.

• For straight cuts, score the panel in one fluid motion from end to end
• Apply firm, even pressure without pressing too hard
• Let the sharpness of the blade do the work, not brute force
• For curved cuts, use scissors with slow, deliberate movements

Directional Guidelines

• Cut away from bus bar connections: When possible, position your cuts to avoid the conductive bus bar edges
• Avoid sharp interior angles: Radius curves (rounded corners) are stronger and easier to seal than sharp 90-degree angles
• Leave bus bar intact: Always ensure at least one edge of the bus bar remains connected for proper power distribution

After Cutting

Do not delay the sealing step. Proceed immediately to seal all cut edges to prevent moisture infiltration and electrical hazards.

Safety Warning

CRITICAL SAFETY ALERT:

Cutting exposes the internal electrode layers of the EL panel. These exposed layers are conductive and can present an electrical hazard if the panel is powered with unsealed edges.

Risk of Electrical Shock

• If the panel is powered while edges are exposed, you risk electrical shock from contact with electrode layers
• NEVER power a panel with exposed, unsealed cut edges
• Always seal all cut edges IMMEDIATELY after cutting, before any power testing

Liability

Ellumiglow is not responsible for injury or damage caused by improper panel handling or use. You assume all responsibility for safely cutting, sealing, and operating custom-cut panels.

Best Practice

When in doubt, consult the Prototyping & Connection Guide or reach out to our support team before cutting your panel.

Sealing Methods

Different sealing methods work for different situations. Choose based on your timeline and durability requirements.

Clear Nail Polish (Quick Temporary Seal)

Best for: Quick prototyping, temporary installations, initial testing

• Clean the cut edge thoroughly with a dry cloth to remove dust
• Apply a thin, even coat of clear nail polish along the cut edge
• Allow to dry completely (typically 5–10 minutes)
• Apply a second coat for better coverage
• Note: This provides temporary protection. For long-term use, upgrade to epoxy

2-Part Epoxy Resin (Permanent Seal)

Best for: Permanent installations, long-term durability, professional finishes

• Clean the cut edge with a dry cloth
• Mix epoxy resin according to manufacturer's instructions (typically 1:1 ratio)
• Apply a generous amount around the entire edge
• Use a toothpick or small brush to ensure complete coverage
• Smooth out excess and create a uniform seal
• Allow to cure per manufacturer (typically 5 minutes to 24 hours)
• For extra durability, apply a second coat once the first has cured

Heat Shrink Tubing (Edge Protection)

Best for: Protecting connection points, bundling and organizing wires

• Slide heat shrink tubing over the cut edge or connection
• Carefully apply heat with a heat gun until the tubing shrinks to fit
• Combine with epoxy for maximum protection at connection points

Conformal Coating (Professional Grade)

Best for: Outdoor installations, wet environments, professional systems

• Apply conformal coating following manufacturer's specifications
• This creates a waterproof barrier over all exposed surfaces
• Commonly used in outdoor signage and marine applications
• Requires more careful application but provides superior protection

Reconnecting After Cuts

If your cut severs an electrical connection, you'll need to reconnect the panel properly.

Using Crimp Connectors

1. Locate the severed edges where the bus bar was cut
2. Strip ½ inch of insulation from each exposed wire
3. Insert the wire into the appropriate crimp connector terminal
4. Use a crimp tool to compress the connector firmly
5. Verify the connection is secure (it should not pull out easily)

Soldering Connections

1. After crimping, apply flux to the connection point
2. Use a soldering iron (350°F / 175°C) to heat both the wire and connector
3. Apply solder until a smooth, shiny joint forms
4. Remove the iron and allow the joint to cool without disturbance
5. Pro Tip: Solder to crimp tabs before attaching to the panel to avoid heat damage

Sealing Connection Points

1. After soldering cools completely, inspect the joint for quality
2. Use a multimeter to test for continuity and proper electrical connection
3. Apply epoxy resin around the entire connection point
4. Ensure no bare metal or solder joints are exposed
5. Allow epoxy to cure fully before powering the panel

Shape Limitations

While EL panels are flexible, certain design constraints apply to maintain functionality and durability.

Avoid Sharp Interior Angles

Sharp 90-degree corners and acute angles create stress points and are difficult to seal properly. Use rounded corners (radiused curves) for better structural integrity.

Minimum Feature Size

Design elements should be at least 0.5 inches (≈12 mm) across. Smaller details become fragile and hard to seal effectively.

Bus Bar Integrity

The conductive bus bar must remain intact on at least one edge of the panel to distribute power evenly. Never completely isolate or separate the bus bar.

Large Cutouts

While you can cut shapes, avoid removing more than 50% of the panel material, as this can affect light distribution and electrical performance.

Material Strength

EL panels are delicate. Very thin or fragile designs may crack or fail during handling. When in doubt, prototype with a larger panel first.

When to Order Custom Panels

Advantages of Custom Manufacturing

If you need multiple identical shapes, complex geometry, or production quantities, ordering custom-manufactured panels from Ellumiglow is often the better choice.

Custom Panel Benefits

• Precision: Manufacturing dies produce perfect shapes every time, with no hand-cutting variations
• Quality: Pre-sealed edges at the factory ensure maximum durability
• Consistency: Perfect for production runs where uniformity is critical
• Cost-Effective at Scale: The more units you order, the lower the per-unit cost
• Safety: Factory sealing eliminates DIY sealing risks
• Durability: Professional manufacturing creates more reliable, longer-lasting panels

The Custom Tooling Process

Tooling Fee: $500 NRE (non-recurring engineering) for custom die creation

• You retain ownership of the tooling screen, allowing for future production runs at standard pricing
• Submit your artwork or design specifications (DXF, PDF, or detailed drawings)
• Our team reviews the design for manufacturability and provides feedback
• Once approved, the $500 tooling fee is charged and production begins
• Future runs using the same tooling do not incur the NRE fee

Design Recommendations

Before committing to custom tooling:

• Prototype first: Use the EL Panel Prototyping Kit to test your shape design
• Test functionality: Verify the shape works as intended, illuminates properly, and meets your requirements
• Confirm production volume: The $500 tooling investment is worthwhile only if you plan multiple units
• Review constraints: Ensure your design meets the shape limitations outlined above

When to DIY Cut vs. Custom Order

Contacting Ellumiglow for Custom Panels

Ready to order custom-manufactured panels? Contact our team with:

• Your design artwork or detailed drawings (DXF, PDF, or physical sketch)
• Desired panel size and quantity
• Preferred color and specifications
• Timeline and production schedule