How We Do It
From artwork to finished sign — a step-by-step look at how our skilled craftsmen handmake every neon sign in our Bolton workshop.
Every neon sign we make is completely handmade by our skilled craftsmen in our workshop in Bolton, Greater Manchester. The process hasn't changed much in more than 100 years — and remains one of the most eye-catching forms of signage in the world. Here's exactly how we do it, step by step.
We work from artwork provided by our client, or produce artwork on behalf of our clients.
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.
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.
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.
Keeping the glass in the hot flame, the glass is bent into the required shape.
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.
The bent glass is continually matched against the drawing to ensure that the design is replicated accurately.
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.
This technique is used for complex scripts and intricate logo work.
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.
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.
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.
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.
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.
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.
The transformer is fixed onto the backing panel or inside the acrylic case.
Tube supports are fixed onto the backing panel to hold the neon sections securely in place.
The separate sections of glass tubing are wired together to make a complete electrical circuit.
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.
Final adjustments are made to the alignment of the sign and the overall look, ensuring everything is perfect before sign-off.
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.
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.
Every sign leaves our workshop individually tested and ready to hang and plug in.
Join one of our neon sign making workshops in Bolton and try the craft yourself — guided by our expert glass benders.