Learn about the process.

The process begins with a design concept. Artists or designers create a digital or hand-drawn illustration of the desired sign, considering factors such as size, color, and overall aesthetic.

Once the design is finalized, a pattern or template is created. This pattern guides the glass tubes into shapes to form letters, symbols, or any other sign elements.

Specialized glass tubes are selected based on the design requirements. The tubes are typically made of lead or borosilicate glass, which can withstand the high temperatures in the neon sign-making process.

The cleaned and coated tubes are then filled with a small amount of gas, typically neon or argon. Neon produces a red-orange glow, while argon emits various colors depending on the phosphor coating used.

Electrodes, usually made of metal like aluminum or coated with a special material, are attached to each end of the glass tube. These electrodes facilitate the flow of electricity through the gas inside the tube.

Skilled craftsmen, known as neon tube benders, use the pattern to guide the glass tubes into the corresponding shapes. This delicate process requires precision to achieve the correct form without damaging the glass.

The ends are sealed once the tubes are bent and the air is evacuated. The remaining air is replaced with the chosen noble gas, creating a vacuum-sealed environment within the tube.

The completed neon tube is then tested to ensure that it lights up correctly and that there are no leaks. This step is crucial to guarantee the sign's functionality and longevity.

The finished neon tubes are mounted on a backing material, such as acrylic or metal, and wired to a power source. The wiring is connected to the electrodes, allowing electricity to pass through the gas and produce the characteristic glowing light.