The fine print
How the calculator works, and where it stops
Legibility is angular. A three-inch letter at 30 feet and a six-inch letter at 60 feet are optically identical — same angle at the eye, same difficulty, same result. That angle is measured in arcminutes, and every published sign chart is quoting the same relationship at a different angle without saying which.
For a viewing distance D in feet and a target angle θ in arcminutes, the required cap height in inches is D × θ ÷ 286.5. At 11.5 arcminutes that gives 25 feet of distance per inch of height; at 28.6 arcminutes it gives exactly 10, which is the familiar rule of thumb. Both are correct. They answer different questions.
Every figure here is cap height, not point size. 72 pt is one inch of em box, and the capital inside it is only about 0.72 inches tall — roughly 28% short. The point-size output above corrects for this using the cap ratio of the typeface you select, but the number you hand a fabricator should always be a cap height in inches or millimetres.
What this tool does not do: it does not check ADA minimums, local sign ordinances, or the sign-area limits in your lease. It does not account for stroke weight, letter spacing, case or contrast — all of which can sink a correctly sized letter. And it assumes good conditions. For the full treatment of all of those, read the signage spec guide on letter height by viewing distance.
Related reading: the print-ready file checklist, vector vs raster explained, and kerning, leading and tracking. If you produce signage artwork commercially, we also run white-label design for sign and banner shops.