How are Neon Signs Made?

How are Neon Signs Made?

Today, neon lights are frequently seen. They are seen everywhere—in commercials, pharmacies, retail establishments, and the flashy lights of the Las Vegas Strip.

From a distance, they truly do pop out and act as a highlighting element for the specific location where they are situated. On the other hand, neon lighting is manufactured differently than most other types of lighting. It's evident why many people prefer using these lights for their homes and businesses. In this article, we will answer the questions that lurk in your mind regarding how custom neon signs are made.

What is a Neon sign?

A neon sign is a type of illuminated sign that uses neon gas to produce light. It consists of glass tubes filled with neon gas, which emits a bright, colorful glow when an electrical current is passed through it. Neon signs are known for their distinctive appearance and have been used for decades in advertising, storefronts, and art due to their vibrant colors and eye-catching qualities. They became particularly popular in the early to mid-20th century and are still used today for their nostalgic appeal and aesthetic charm. 


Because they are inert gases, both are harmless, stable, colorless, and odorless. Therefore, they have been utilized for an exceptionally long time in household applications like lighting. Strip lights, which include tubes that aren't visible but are intended to light up other objects, like the interior of a built-up letter, were originally only employed as illumination sources.

Nowadays, you can find multiple-category neon signs online. You don't need to know the entire process of manufacturing these lights, as you can purchase them online. The amazing designs of these neon light flows liven up and enliven the spaces where they are placed.

How are Neon Signs Made?

The letters and shapes that neon signs are made of are made by bending glass tubes and then filling them with inactive gas. The gas's atoms light as electrons passes through it because of the electric charge passing through the tube electrodes. How the light is colored depends on the kind of gas in the tubes.

Neon Sign

 

Red light is produced by neon gas in a glass pipe, and steel blue light is produced by argon gas. By utilizing glass tubes covered in fluorescent powders, you can combine the two basic hues to generate over 80 distinct colors for vibrant artwork.

When comparing fluorescent vs. neon lights, it's evident that neon lights provide a broader and more vivid color spectrum, making them a superior choice for eye-catching signage and artistic displays.

You must form the tubes using a glass-gusting method to make a neon sign. Label the tubes anywhere they need to be bent by following a design drawn on a fire-resistant sheet. Next, use a tape burner—a device that heats each spot—to generate a propane fire at 1200 degrees Fahrenheit. The glass gets sufficiently pliable in approximately thirty seconds. The tube is gently bent, and the original diameter is restored by blowing air through the opened end.

Fuse the electrodes using a plastic latex blowing pipe and a propane hand flame. One electrode has its glass sealed, while the other is left open.

After that, make a tubulation—a bubble—with a crossfire burner to serve as a conduit into the exposed electrode. The tubulation is then fused to the exposed electrode. The argon gas's color is now brightened by adding a droplet of mercury to the tubulation. Mercury plays a key role because argon gas won't shine well without it. Nevertheless, Neon gas doesn't require mercury.

Fuse the tubulation's open end into a lengthy glass pipe that connects to a thrusting mechanism using an end torch. When the system is powered on, we join the electrodes. Before injecting the gas, the pump removes all the air from the neon sign.

Atoms in the gas light are caused by electrical current. After removing and sealing off the exposed electrode with the crossfire burner, first ensuring that the mercury drop has landed within the electrode, you can trap the gas within the tube.

The neon sign's back will now be painted black to make the writing and design unique. You will utilize a brush for proper coat distribution and excess removal. Next, for almost half an hour, turn on the sign at full voltage. This will not only cause the paint to dry but also turn the mercury vapor inside the neon sign from liquid into vapor. While the process might look tasking, at least you know what are neon signs made out of looking through the production process.

Factors Affecting Neon Sign Color

Factors Affecting Neon Sign Color

 The neon sign-making process is just a piece of the puzzle. You need to know the factors that affect the sign color if you want your light to last. There are three factors that might affect your neon sign color.

  • Gas used: If you use neon gas, you should expect to see red color. However, for other colors, you should use argon gas.
  • The gas coloring process: Glass that is colored yellow is the sole material that can be used to make certain colors, like yellow. When turned off, the neon sign retains its color, which is an advantage; however, the glass becomes marginally more costly.
  • Powdered glass: When switched off, most "neon" glass is white. This is because the interior of the glass tube has been coated with fluorescent powder. The powder applied within the neon tube determines its color when a current is run via the glass, and the neon gas begins to emit light. Most colors, including turquoise, pink, white, and green neon, are produced this way.

Overall, the gas used, the gas coloring process, and the powdered glass will affect the materials used to make neon lights.

Understanding the psychology of neon sign colors is essential. For example, red can create a sense of excitement or urgency, while blue is known for its calming and welcoming effect. Choosing the appropriate color can significantly enhance the desired impact and effectiveness of the neon sign.

What more?

Neon sign design has advanced recently, with small electrical transformers eliminating the noticeable hum of previous neon signs. Programmable electronic controls have replaced the previous electromechanical cam-and-switch controls for controlling neon lights that blink or appear to move. 

Back to blog