From the “vacancy” sign at a roadside motel to the brilliance of the Strip in Las Vegas, neon signs have long been prominent in American signage. With the rising popularity of cheaper lighting, the classic appeal of neon signs is on the rise. But another aspect of what makes them so special is the care with which they are crafted. The team members at Burchette Sign Corporation, serving Colfax, Winston-Salem, Greensboro, and Charlotte, NC, have been creating custom signs since 1960 and are experts in this historical craft. Here is their step-by-step explanation of how custom-made neon signs are created.

How Classic Neon Signs Are Made

1. Plan

First, an artist draws a design and prints it on fireproof paper. Then, they mark one or more glass tubes where they will need to be bent.

2. Shape

Using a combination of torches and blown air to control the temperature, a bender, the term for a neon sign artisan, shapes the glass tubes by hand. After each bend, they check the tube against the design template.

3. Fill

Once the tube is shaped correctly, the artisans attach the whole apparatus to a pumping system, which removes the air and replaces it with a noble gas, such as neon, argon, or xenon. With the gas trapped inside, electrodes are placed at either end of the tube, and it is sealed.

4. Refine

Because a neon sign is one uninterrupted tube, certain areas are painted over to create the illusion of a gap between letters. The bender then mounts the sign onto a bracket and attaches transformers to the electrodes at either end. When electricity passes into the electrodes, it charges the noble gases inside, causing them to glow. The type of gas and coatings in a neon sign determine the color it glows.

Because of their unique blend of physics and artistry, neon signs convey a deeper meaning than the simple words or images formed by their glowing tubes. Making neon signs is a painstaking process that takes years to master, and the resulting signage can have a unique impact on any building or room. If you are interested in learning more about their range of neon signs, custom banners, and car wraps, call Burchette Sign Corporation at (336) 996-6501, or visit them online or on Facebook to view a gallery of their recent work.