How are LED neon signs designed?

In traditional neon signs, soft lead glass (crystal) is heated, bent and twisted by hand, then cooled and fused.

They are later filled with various gases to achieve different colours.

Pure-iron electrodes surrounded by a glass jacket are welded to both ends of the tube and wired to the transformer using high-voltage cables.

The glass tubes are then mounted to a backing panel.

Faux neon signs (LED neon) signs have a different manufacturing process than traditional glass tubing neon signs.

Rather than using glass or neon gas, LEDs are designed from made from acrylic—a thermoplastic better known as Altuglas or Perspex.

Designing a LED neon sign consists of the following steps:

• Our team machine the sign’s backing out of acrylic, metal or wood. The acrylic tubing that will hold the LEDs is cut.
• The cut parts are then prepared and ready for paint or vinyl.
• Depending on the intricacy of the design, the sign is then either painted or finished with vinyl. Most often, we paint very detailed designs.
• Low-voltage LEDs are closely embedded together inside the tubing.
• The parts of the sign are put together and mounted onto a backing board.

• The sign then goes through an extensive quality control process, ensuring the sign appears perfect and is of the highest quality.