Neon Signs: a full guide to how they work and what you need to know before buying one

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.

In traditional neon, there is an electrode at either end of the tube—one is negative, and one is positive. The gas inside a traditional neon tube is a noble gas, which means it only undergoes chemical reactions under high-energy conditions. When the gas comes into contact with electricity, it undergoes a chemical reaction. If you apply an alternating current to the electrodes, the electricity creates enough energy for the neon atoms to separate inside the tube.

Some electrons become positively charged ions, which fly towards the negative electrode. The free electrons have a negative charge and are drawn towards the positive electrode at the other end of the tube. As the neon atoms, ions and electrons bounce around the tube, they collide with each other, gradually increasing in energy. When the ionised atoms recapture their electrons to become neutral again, they release a particle of light known as a photon, which is what causes neon to give off a bright, coloured glow.

With LED neon, the reaction comes when electrons pass through a semiconductor, which is typically a material known as aluminium-gallium-arsenide. The LEDs must be positioned close to each other so they produce a steady source of light. This is similar to the effect of neon gas glowing inside a glass tube.

• LED neon signs can change colour, unlike traditional neon. You can read more about how LED neon signs can change colour here.
• LED is regarded as a safer and more environmentally friendly choice.
• LED neon signs provide a lightweight, shatter-resistant alternative to traditional neon. Acrylic is lighter and stronger than glass and if broken, will not shatter into small pieces as glass does. As they are designed with acrylic neon tubing, they are also more robust.

• Acrylic is optically clear and provides a “glass effect”.
• Acrylic neon signs are significantly less expensive to run than traditional neon. The signs provide 80% reduced running costs in comparison to traditional neon.
• With the addition of thermally managed LEDS, the faux neon system runs cool to the touch.
• LED signs generate little heat. LED neon signs generate little heat and are safe to touch, unlike neon signs that become extremely hot when on.
• The range of colours available for LED signs is almost limitless. This makes it easier to express image more closely is easier because of this, maintaining brand integrity.

• LED neon provides brighter and more consistent light than neon and can be seen further away.

You can read a full list of the pros and cons of LED neon and traditional neon here.