The Neon Process

Finally, all the units for the sign go to the Assembly Table where they are mounted for hanging. Usually, we use a lightweight black PVC material because the neon will show up best against black, but we also use clear or colored materials, and sometimes even wood or stone. A “transformer” is attached to the back of the sign to provide the high voltage the neon requires, then each unit is wired to the next to create a continuous circuit.

How Neon Is Made

We’ve provided a step by step explanation of our working process to help familiarize you with Neon and the possibilities that can arise by using this special craft.

Below you will find a unique window into part of what makes customized neon projects such an attractive and practical medium.

Once a design has been selected, the first step is to create a working pattern. In the example shown, we are making a sign that will say “Valhalla Dental” with a viking ship. A working pattern is done actual size on paper, and becomes the template used to bend the neon tubes. It shows the size and color of glass to be used, areas to be blocked out, and specifications for mounting.

When the pattern is complete it goes it the bender, and the glass tubes are bent to the pattern. To facilitate the entire process, the pattern is broken down into separate UNITS, each of which can be lit independently. In our example we have 5 units.

After being bent to shape, each unit gets electrodes on both ends and then moves to the next step.

At the Bombarding Table, each unit is put under vacuum and heated to high temperatures to eliminate any impurities in the tube. Then, either neon gas (which is red in color) or argon gas (which is blue) is metered in.

The many possible combinations of glass tube color and gas color create a broad color palette to work with. In units with argon, a drop of mercury is also added inside the tube to intensify the light. Now the unit can be removed from the vacuum manifold and it will light with the beautiful color and intensity that we all recognize as “neon”.

All bomarded units are moved to the Aging Table where two things happen. Each unit of glass either gets dipped or hand painted to block out parts that should not light, such as where one letter is connected to another. Then the finished unit is allowed to “age in”, or sit in the lit state to ensure it will burn correctly for years to come.