Abstract: A single pass process and apparatus for manufacturing a folded yard sign from a pre-cut sheet previously coated on both sides with a fusible polymer includes the steps of printing an image on an outside of the sheet, curing the image, scoring the printed sheet, folding the scored sheet, ultrasonically sealing regions along side edges of the folded sheet, and stacking the sealed sheets, which are finished sign products ready for packaging. The ultrasonic sealing fuses the polymer coated inside surfaces along the edges of the folded sheet. The sealed side edges form a sign support receiving pocket in the finished sign member in cooperation with a folded edge of the sign member.