Creating custom neon signs is an intricate and creative process that involves several steps, from initial concept design to the final installation. The art of making neon signs has evolved over the years, and modern technologies have made it more accessible, but the essence of craftsmanship and creativity still remains at the core. Below is a breakdown of how neon signs are made, from concept to creation: For more information please visit custom neon signs

1. Concept and Design

The first step in creating a custom neon sign is developing a concept. The client or designer typically provides a general idea or vision of what they want the sign to represent. The design phase includes:

  • Choosing Text or Artwork: The client may want the sign to display a logo, slogan, name, or an image. This is the starting point of the design.
  • Typography and Style: Choosing the right font, letter spacing, and style of the text is important. For more artistic designs, custom graphics or logos may also be created.
  • Color Selection: Neon lights come in a wide range of colors. The color choice is essential for setting the right mood or making the sign stand out.

Designers usually create a digital mockup of the sign, showing what it will look like once completed. This helps clients visualize the final product before moving to the next steps.

2. Material Selection

Once the design is confirmed, the next step is selecting materials. In traditional neon signs, glass tubes were used, but modern designs may utilize LED neon flex for a more energy-efficient alternative. The material chosen will depend on factors such as:

  • Glass Tubing (for traditional neon): High-quality, flexible glass tubing is used for bending into the desired shapes.
  • LED Neon Flex (for modern LED neon signs): These are flexible, durable, and much easier to work with compared to glass.
  • Power Supply and Controller: Neon signs require a power supply, and if customization is needed (e.g., dimming or color changing), a controller will be used.

For traditional glass neon, neon gas (usually neon or argon) is filled inside the tubes. For LED neon, strips of flexible LED lights are wrapped in a silicone or PVC covering.

3. Bending the Tubes

For traditional neon signs, the bending of glass tubes is one of the most skillful and delicate processes. The steps include:

  • Heating the Glass: Glass tubing is heated to a pliable temperature, allowing it to be bent without breaking.
  • Shaping the Tubes: Skilled craftsmen use special tools and jigs to bend the glass into the desired shapes according to the design.
  • Adding Electrodes: Once the tubing is shaped, electrodes are attached at both ends of the glass tubes. These are necessary to send the electrical charge that will light up the neon gas inside.

For LED neon signs, there is no bending required, as the LED strips are flexible and can be arranged along the contours of the design.

4. Sealing and Filling

After the tubes are bent, the next step is to seal the glass and fill it with the appropriate gas. Neon gas or a mixture of neon and argon is used for the traditional neon effect. The gas creates the characteristic neon glow when an electric current passes through it. The process involves:

  • Filling the Glass Tubes: The glass tubes are evacuated of air and then filled with the neon or argon gas.
  • Sealing the Tubes: The open ends of the glass tubes are sealed, and the electrodes are connected to ensure the flow of electricity.

LED signs do not require filling with gas, but LED neon flex strips are assembled and wired.

5. Testing the Sign

Once the tubes are bent, filled, and sealed, the sign is tested to ensure it works properly. Electric current is passed through the neon tubes (or LED strips), and adjustments are made if necessary to ensure an even light output.

  • Traditional Neon: If using traditional neon, the glow should be vibrant and consistent across all areas of the design.
  • LED Neon: For LED neon, the lights should illuminate evenly along the flex strip.

6. Mounting and Framing

After the sign has been tested and is working correctly, the next step is mounting the neon light to a frame. The frame holds the neon tubes or LED strips in place and ensures that the sign is secure.

  • Custom Frames: For larger signs or ones with intricate designs, custom metal or acrylic frames are built to support the neon elements.
  • Mounting to the Wall: Signs can be mounted to walls, hanging from the ceiling, or framed in a way that suits the client’s needs.

7. Final Touches and Installation

After the sign is mounted, the final touches are added, including any extra features like dimming controls, color changers, or motion sensors (for animated signs). The sign is then prepared for delivery and installation.

  • Wiring and Electrical Work: The sign is wired to a power source, ensuring that it functions as expected. Proper electrical insulation is used for safety.
  • Installation: The neon sign is installed in the desired location, whether in a business, a home, or an outdoor setting. Professional installers may be needed for large or complex signs.

8. Maintenance and Care

While neon signs are known for their durability, they require occasional maintenance. This can include cleaning the tubes, replacing broken glass sections, or addressing electrical issues. LED neon signs generally require less maintenance and are more energy-efficient than traditional neon.

Conclusion

The art of making custom neon signs is a blend of creativity, craftsmanship, and technical skill. From concept to creation, each sign is unique and involves a carefully planned process. Whether you choose traditional glass neon or modern LED neon, a custom neon sign can add a striking visual element to any space or business, creating a vibrant atmosphere and lasting impression.