The Process of Making a Neon Sign

The Process of Making a Neon Sign


BeneonUnicorn has been manufacturing one-of-a-kind neon displays for commercial and private clientele for many years. 

Whether you need a neon sign for a business, restaurant, or another establishment, you've come to the right place since we can make signs tailored to your specifications. 

We can assist you if you require signage for a storefront, restaurant, or other business.

There must be a cutting-edge strategy for manufacturing neon signs in today's more digital environment. 

In actuality, we handle every part of the design and production processes internally. 

For the last two centuries, the procedure has seen only a few minor modifications here and there. 

We work diligently to bring each customer's vision to reality, and as a result, our finished products are always remarkable due to our exceptional craftsmanship.


But what is the issue with neon? 


Exists a way to transform a mediocre first draught into something truly remarkable? 

Please continue reading to learn more about our experience with neon sign design and creation.


The First Steps Required to Create a Neon Sign


You, the buyer, are the initial source of inspiration for each neon sign

It is acceptable if you are initially uncertain; you can peruse our vast store of ideas and select something piques your interest. 

If you need assistance with the artwork design for your custom neon sign, we can also provide it.

We will then be able to construct a glass blueprint of the neon sign, complete with its exact dimensions. 

Alternatively, we drew it backwards so that any potentially sensitive information would be on the back. 

Next, we will verify that the dimensions of the glass tubing correspond to those on the plan, and then we will mark the locations on the blueprint where the glass will be bent.

We stock glass in a wide range of thicknesses, ranging from 8mm to 25mm, in straight 1.5-meter lengths. 

In most instances, a 10-millimetre diameter is utilised. 

Straight glass tubing is heated over an open flame so it can be moulded to one's liking. 

Depending on the neon sign's final colour, we will utilise clear glass, powder-coated glass, or coloured glass. 

To achieve the correct shape, we maintain the glass in a flame during the entire bending process.

The glass is then re-heated as soon as possible by exposing it to a second, much lower-temperature flame. 

Periodically, the glass is compared to the original blueprint to ensure an exact replica of the design is manufactured. 

Occasionally, we will make a portion of the design separately, such as teeny-tiny letters, and then use heat to integrate it with the rest of the pattern. 

This technology enables the fabrication of more detailed neon signage.


Technology for the Production of Neon Signs in Several Phases


At this point, the procedure for creating a neon sign shifts into a more scientific phase. 

After the glass tubes have been fashioned to our satisfaction, electrodes will be affixed to both ends. 

A vacuum pump is then utilised to remove any remaining air from each compartment.

High-voltage electricity is then given to the tubes, causing both the tubes and the electrodes to heat up. 

The various glass components are then infused with a gas such as neon or argon. 

The type of gas that must be used to produce a particular hue is defined by the hue itself; argon gas is necessary for most hues, whilst neon gas is often reserved for the manufacture of red

The pumped glass is suspended from a transformer in a specific area of the plant known as the ageing bay. 

As a result, a natural ageing process occurs, assuring that all gases have been used. 

At this phase, we apply a layer of opaque paint to the glass to prevent some portions from turning transparent. 

These elements of the sign do not need to be illuminated, such as the backs of the letters and the spaces between the various sign components.




Finally, the exciting phase of creating a neon sign has arrived. At this stage, it is necessary to assemble the neon parts. Frequently, this is done within or on top of an acrylic display box or panel.

Transformers and tube supports attached to the box's back panel hold the neon tubes in the correct locations. 

When the different lengths of glass tubing are connected with wire, the resulting structure can be utilised to create a circuit. 

Before cables can connect the wires to the transformer, the wires must be shielded with protective coatings and insulated with silicone.

There it is, after a few last-minute adjustments to ensure its perfection! 

The finished product is activated and may be hung on the wall immediately. 

At BeneonUnicorn, we enjoy blending neon with various materials, such as prints, mirrors, and even wood, to create a truly one-of-a-kind appearance. 

Here is just one example of how we can make neon appear distinctive. Contact us immediately to place an order for your custom neon sign!