01 · The Finished Sign

ADHIS CYCLE LAB — an open-front LED channel-letter sign, 557 by 397 millimetres, nineteen printed parts. This page rebuilds it the way it was actually made.

  1. The Finished Sign: ADHIS CYCLE LAB — an open-front LED channel-letter sign, 557 by 397 millimetres, nineteen printed parts. This page rebuilds it the way it was actually made.
  2. Idea to CAD: The whole sign is parametric: change one wall thickness or the overall width and every letter, hole and return regenerates. What you see is the real model.
  3. The Parts: Nineteen channel pieces — letters, monogram, bicycle line-art and two subtitle bars. Open fronts, 2.6 mm returns, 2.2 mm back plates, each printing flat with no supports.
  4. Underside: Tilt under the sign and the construction shows: hollow channels, floor holes for mounting, and a 6.8 mm wire pass-through at the base of every letter.
  5. LED Routing: A single 12-volt strip seats on each channel floor and daisy-chains letter to letter through the base holes — one continuous run behind the backer board.
  6. Assembly: Back-flat mounting on the return edges, aligned with a one-to-one printed template. Power it and the open fronts glow.
FAV Design Studio logo

FAV Design Studio

Your Idea, Made Real.

Custom products, from your idea to a real, finished thing.

FAV Design Studio is a Toronto additive-manufacturing studio. A customer brings an idea, shapes it in a live design studio, sees the price instantly, and receives a real, personalized product. See it. Shape it. Make it yours.

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Mission

Transform imagination into real, personalized products through a premium design experience.

Vision

Make custom manufacturing feel personal, visual and exciting.

  1. Idea
  2. Visual Design
  3. Customization
  4. Production
  5. Finished Product

What I built

  • A live 3D design studio in the browser: upload a logo, separate it into print colours for multi-material printing, position it, and export a print-ready file
  • An instant CAD price calculator — material by volume by colour by finish by quantity by channel — so a customer sees the real price before ordering
  • Parametric CAD (CadQuery / OpenCASCADE STEP export) that turns a wordmark or spec into a manufacturable model
  • A material library of 36 PLA options and platform-specific parts for Sur-Ron, Talaria, Stark Varg and other e-bikes
  • A calibration and quality-control regime on Bambu hardware, and a self-hosted order pipeline with live print-progress tracking

Customer and B2B value

For a customer, the value is seeing and shaping the design before it exists, then receiving a real, personalized product. For a business, FAV Design Studio is a small-batch manufacturing partner for signage, branded parts and custom fittings — priced from real material and print cost, not guesswork.

Products range from LED channel-letter signage to Sur-Ron front plates, keychains and valve caps — each taken through the same idea → design → customization → production pipeline. A monthly and quarterly plate-refresh subscription is offered for repeat customers.

From idea to finished product

  1. IdeaA customer arrives with a logo, a sketch, a bike model or a rough description.
  2. Design studioThey shape it live in the browser — colours, text, placement — and see it in 3D, not as a quote request that disappears into an inbox.
  3. Instant quoteThe CAD calculator prices it from real material, volume, colour, finish and quantity — no guesswork, no waiting.
  4. ProductionParametric CAD produces a manufacturable model; it prints on calibrated Bambu hardware with a QC pass.
  5. DeliveryThe finished, personalized product ships, with live print-progress tracking along the way.

One case: ADHIS Cycle Lab LED signage

ADHIS Cycle Lab is a customer. It is one project under LED signage, not the FAV Design Studio identity. It makes a useful worked example because it shows the whole pipeline: a client brief, parametric CAD, slicing and printing, and a finished, installed sign.

The work

A bicycle service shop needed storefront signage. I built a parametric generator that turns any wordmark into printable channel-letter parts: glyph outlines become hollow channels with returns, back plates, wire pass-throughs and mounting holes placed automatically, sized to fit a 256 mm print bed.

The output is manufacturing-ready: nineteen parts that print flat without supports, assemble against a printed one-to-one template, and take a single daisy-chained 12-volt LED run. This is the FAV Design Studio idea in one project — imagination in, real personalized product out.

Build specification

Sign size
557 × 397 × 32 mm
Parts
19 printed channel pieces
Channel
2.6 mm return, 30 mm depth, open front
Back plate
2.2 mm with Ø6.8 mm wire pass-throughs
Lighting
12 V COB LED strip, one daisy-chained run
Printing
PLA, 0.2 mm layers, back-plate down, no supports
Lit elevation preview of the ADHIS CYCLE LAB sign, generated from the parametric model
Lit elevation — real generator output, not an illustration.
Section drawing of the channel profile showing wall, LED strip seat, depth and back plate, with the parts tiling map
Channel section and parts map — the construction the 3D scene above tilts to reveal.

In one sentence: I turned a shop's name into a printable, wired, installed LED sign through a parametric pipeline — idea, CAD, slicing, printing, LED routing, assembly — and every model on this page is the real production geometry.

Back to the Work