How Are Neone Signs Made?

Neon signs are icons of retro charm, man cave ambiance, and nightlife nostalgia. Whether it’s the glowing “Open” sign in a diner window or a custom beer sign lighting up your garage bar, these luminous creations carry an irresistible energy. But have you ever wondered: how are neon signs made?

In this blog, we’ll explore the fascinating science, craftsmanship, and step-by-step process behind neon signs. We’ll also dive into what makes neon different from other types of lighting—and why it's still a top choice for custom bar and man cave décor.

A Quick History of Neon Signs

Before we break down how neon signs are made, it’s worth knowing a little about where they came from. Neon lighting was first demonstrated by French engineer Georges Claude in 1910. By the 1920s, neon signs were being used for advertising across Europe and the United States, quickly becoming a symbol of modern commercial flair.

Today, neon signs still maintain their timeless appeal—even as LED technology grows. That nostalgic glow remains unmatched in creating a warm, retro vibe.

What Is Neon, Exactly?

Neon is a noble gas found in Earth’s atmosphere. When sealed inside a glass tube and electrified, it emits a reddish-orange glow. However, neon isn’t the only gas used in these signs. Other noble gases like argon, krypton, and xenon can produce different colors when combined with phosphor coatings.

Fun Fact: Pure neon gas emits a bright red-orange light. To get other colors (like blue, green, or purple), different gases or coated tubes are used.

The Step-by-Step Process: How Neon Signs Are Made

Creating a neon sign is part science, part art. Here's how it all comes together:

1. Designing the Layout

Every neon sign starts with a design. Whether it’s a custom name, phrase, logo, or shape, artists lay out the final look—often using a full-size pattern printed on heat-resistant paper. This template guides the glass bending process.

The design also determines the number of tubes needed, gas types, and power supply requirements.

2. Glass Tube Selection and Preparation

Neon signs are made using long, hollow glass tubes—usually between 4 to 5 feet in length. The glass comes in various diameters and colors (clear, tinted, or phosphor-coated).

Before bending, the tubes must be:

• • Cut to size based on the design
  • Cleaned to remove any dust or residue that could interfere with the vacuum process later
  • Marked to identify the specific bends and twists

3. Glass Tube Bending

This is where craftsmanship really shines. Skilled neon benders heat sections of the glass over a ribbon burner or crossfire flame until it softens. Then, they bend the tube into shape using a combination of gravity, breath, and manual force—all while aligning it precisely to the pattern beneath.

This process takes years to master. If a bend is done too quickly or unevenly, the glass can kink or crack.

Important Step: After each bend, the artisan blows into the tube to keep the inner diameter from collapsing.

4. Electrode Attachment

Once all the bends are complete and the tube has cooled, electrodes are attached to both ends. These electrodes will eventually conduct the electric current that excites the gas inside.

The ends of the glass are sealed around the electrodes using a flame to fuse the materials together.

5. Tube Bombarding and Gas Filling

This is one of the most technical steps in the process.

• • Bombarding involves heating the tube with a high-voltage current to remove any remaining contaminants and moisture. This purifies the inside of the tube for optimal performance.
  • After bombarding, the tube is evacuated using a vacuum pump.
  • Then, the desired noble gas (neon, argon, krypton, etc.) is introduced at a precise pressure level—typically measured in millitorr.
  • Once the tube is filled, it’s sealed off permanently.

Gas + Vacuum = Glow. This combination allows electricity to excite the gas atoms, creating visible light.

6. Testing and Aging

The newly filled neon tube is tested and “aged” by running electrical current through it continuously for several hours. This helps stabilize the gas and ensures an even, consistent glow.

If there are any issues—like flickering or dead spots—the tube may need to be re-bombarded or refilled.

7. Mounting and Wiring

Once the neon tubes are finalized, they’re mounted onto a backing material—commonly acrylic, metal, or clear glass. Clips and insulators hold the tubes in place without risk of electrical shorts.

Wires are connected from the electrodes to a transformer, which converts standard electrical voltage into the high voltage needed to power the gas.

8. Final Assembly and Safety Check

After the wiring is secured, the transformer is tested, and the final sign undergoes a full quality control inspection. Safety is a top concern with neon signs because they operate at high voltage and can heat up during extended use.

Once approved, the sign is ready for delivery and installation!

Neon vs. LED: What’s the Difference?

While neon signs are made using gas-filled glass tubes, LED signs use light-emitting diodes housed in flexible plastic tubes. Here’s a quick comparison:

Both are popular in bar décor, home man caves, and retail signage. However, neon still holds a unique place in vintage aesthetics and custom craftsmanship.

Why Neon Signs Are Perfect for Man Caves

There’s something timeless about a glowing neon sign hanging above your home bar or pool table. Here's why they remain a top décor choice:

• • They create atmosphere – That warm, colorful glow sets the mood instantly.
  • They showcase personality – Whether it’s a beer logo or your favorite saying, custom neon signs make a space yours.
  • They’re conversation starters – Everyone loves a good neon sign photo-op.

If you're creating the ultimate man cave, a neon sign isn’t just décor—it’s an experience.

Bright Ideas in Every Tube

So, how are neon signs made? Through careful design, skilled glass bending, scientific gas filling, and high-voltage magic. Each sign is a blend of artistry and physics—a glowing tribute to craftsmanship that continues to shine in a world full of LEDs.

Whether you're shopping for a ready-made beer sign or dreaming of a custom man cave masterpiece, understanding the process behind it makes the glow that much more special.

Looking for Custom Neon for Your Man Cave?

At The Beer Lodge, we’re all about making your hangout space epic. Browse our collection of bold, brilliant LED and neon-style bar signs, or design your own custom look today!