HOW IS
IT MADE

Step 1: Artwork & Design

We work from artwork provided by our client, or produce artwork on behalf of our clients.

Step 2: Glass Drawing

A full size glass drawing is created from the artwork. This is always made in reverse, so that when the sign is made, the parts that need to be hidden are at the back.

Step 3: Measuring The Glass

The glass tubing is measured against the drawing and marked where it needs to be bent. The glass comes in straight lengths of 1.5m, in diameters ranging from 8mm to 25mm. We mainly use 10mm diameter for our work.

Step 4: Heating The Glass

The straight piece of glass tubing is heated in a flame. Depending on the colour of the sign, either clear glass, powder coated glass, or coloured glass is used.

Step 5: Bending The Glass

Keeping the glass in the hot flame, the glass is bent into the required shape.

Step 6: Cooling The Glass

Once the required shape has been made, the glass is put into a cooler flame to help it cool down quickly and set the bend correctly.

Step 7: Matching Against The Drawing

The bent glass is continually matched against the drawing to ensure that the design is replicated accurately.

Step 8: Joining Small Sections

Sometimes, if there are lots of small letters or smaller parts of a design, these may be made individually and then joined together. This is done by heating the glass on both sections and fusing them together.

Note: This technique is used for complex scripts and intricate logo work.

Step 9: Fitting The Electrodes

Electrodes are put onto both ends of each section of glass. These are essential for allowing the electrical current to pass through and ignite the gas.

Step 10: Vacuum Pumping

Air is removed from the glass sections by a vacuum pump, and then the tube is subjected to high voltage electricity, making the tubes and the electrodes get very hot.

Step 11: Gas Filling

The sections of glass are then pumped with either neon or argon gas, depending on the final colour of the sign. The majority of colours use argon gas, with red being the main colour that uses neon gas.

Step 12: Ageing In

The pumped sections of glass are hung up in the ageing bay and connected to a transformer. This is for the process of 'ageing in', to ensure that the gases have burnt in enough for a consistent and lasting glow.

Step 13: Block Out Paint

Parts of the glass section are painted with block out paint so that light does not shine through unwanted areas — generally the backs of the letters and the spaces between them.

Step 14: Assembly Begins

The neon sections are assembled — usually into an acrylic case or onto an acrylic panel. Tube supports, a transformer, silicone end covers, and HT cable are used in the assembly process.

Step 15: Fixing The Transformer

The transformer is fixed onto the backing panel or inside the acrylic case.

Step 16: Fitting Tube Supports

Tube supports are fixed onto the backing panel to hold the neon sections securely in place.

Step 17: Wiring The Circuit

The separate sections of glass tubing are wired together to make a complete electrical circuit.

Step 18: Covering The Wires

The bare wires are covered by silicone end covers, and the cables from the glass sections are wired up to the transformer to complete the circuit safely.

Step 19: Final Adjustments

Final adjustments are made to the alignment of the sign and the overall look, ensuring everything is perfect before sign-off.

Step 20: Switch On!

The finished sign is switched on. As can be seen from this sequence, neon signs are totally handmade by a skilled craftsman — every single one.

Step 21: 100 Years Of Craft

The process hasn't changed much in more than 100 years, yet has remained one of the most eye-catching forms of signage. At Neon Creations we are constantly striving to develop the uses of neon — incorporating vinyl, mirrored products, different acrylics, and printed media.

Note: Every sign leaves our workshop individually tested and ready to hang and plug in.