Hale Custom Signs, Inc.
Neon project built by Hale Custom Signs in Massachusetts

Neon

Hand-bent neon

Nothing imitates neon. Not LED strip, not flex tube, not a printed face with a glow effect. If you want the real thing, it has to be bent by hand over a flame.

What it is

Neon is a craft that most sign shops stopped doing thirty years ago. We did not. Glass tube is heated over a ribbon burner, bent to a full-size pattern drawn on the bench, electrodes are sealed on, the tube is pumped down, filled with neon or argon, and bombarded. Then it either lights evenly or it does not, and you start again.

That process is why real neon looks the way it does. The light comes from the whole length of the tube at once, so it wraps and glows rather than pointing at you. It has a depth that LED cannot fake, and on a bar, a salon, a cafe or a storefront window it still stops people in a way nothing else does.

We also keep older neon alive. A great deal of our neon work is restoration — re-bending a cracked section, replacing a failed transformer, cleaning and re-mounting tubes that have been dark for years. If you have inherited a neon sign with a building, bring us a photograph before you assume it is beyond saving.

Materials & construction

How we build it

Hand-bent glass

Tube bent over a flame to a full-size pattern. Every corner and every letter is shaped individually.

Colour range

Neon gas for the reds and oranges, argon with mercury for blues and greens, plus coated tubing for the rest of the spectrum.

Restoration

Cracked sections re-bent and matched, dead sections replaced, mounts and standoffs rebuilt.

Transformers & GTO

Failed transformers replaced, high-voltage wiring renewed, housings made safe and weathertight.

Step 01Full-size pattern

The design is drawn at actual size on the bench — the glass is bent to the drawing, not to a screen.

Step 02Bend & seal

Tube is heated, bent, electrodes sealed on, and the assembly checked for fit against the pattern.

Step 03Pump & fill

Evacuated, bombarded, filled with the right gas at the right pressure, and aged until it burns clean.

Step 04Mount & wire

Tubes mounted on supports, wired to the transformer, housed, and tested before it leaves the shop.

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Common questions

Neon FAQs

For pure output per watt, no. For appearance, there is no contest — real neon glows in a way LED tube does not, especially at night and especially reflected off glass or brick. If the look is the point, buy neon. If you just need brightness, buy LED and we will build you that instead.

Usually, yes. Cracked tube can be re-bent and matched, failed transformers are a standard replacement, and dim tubes can often be restored. Send a photograph and a description of what it does when you switch it on and we will tell you honestly whether it is worth the work.

A well-made tube run at the correct current can last twenty years or more. Transformers are the usual failure point long before the glass is. Neon that has gone dim rather than dark is often just a transformer.

Yes, when it is installed correctly. The tubes themselves run cool enough to touch; the high voltage is in the transformer and the GTO cable, which we house and route properly. Interior neon is a standard part of what we build.

Close to it. Neon gas gives you the reds and oranges, argon with a mercury drop gives blues and greens, and coated tubing extends that to most of the spectrum. Some colours are brighter than others, and we will tell you which ones fade fastest.

Ready when you are

Let’s price your neon

Send us the dimensions, the location and anything you have already sketched. We will come back with a real number.

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