LED neon signs may look sleek and effortless once they are shining on your wall, but behind each design is a careful and detailed process carried out by a skilled production team. At Neon Daddy, every sign is crafted with precision tools, high quality materials and plenty of hands on expertise. Here is a behind the scenes look at how your custom neon sign comes to life.
Step 1: The Design Stage
Every sign begins with a digital concept created using CAD, also known as Computer Aided Design. This is where your artwork, lettering or logo is translated into a technical drawing that can be read by our manufacturing machinery. CAD ensures accuracy, helps us plan the layout and allows us to preview how the sign will look once built.
A well prepared CAD file also helps determine the size, shape and complexity of the acrylic board that the sign will be built on. Once approved, it moves from the design desk to the workshop floor.
Step 2: Manufacturing the Sign
Precision Cutting
Your chosen design is carved from premium acrylic using CNC, which stands for Computer Numerical Control. CNC machinery follows the exact instructions from the CAD file, cutting clean and smooth grooves that will later hold the LED strips.
Each board yields around five to ten signs depending on size and complexity, and every cut is accurate to the millimetre. This level of precision ensures a perfect fit for the LEDs and flawless visual alignment in the final product.
LED Installation
Once the acrylic is ready, our team begins the process of installing the LED strips into the cut grooves. This step requires both technical skill and artistic judgement.
We take great care to avoid dark patches, bright spots or uneven lighting. By spacing the LEDs correctly and selecting the right colour temperature, we achieve a smooth and consistent glow throughout the entire sign.
Wiring and Power Setup
After the LEDs are installed, the wiring begins. The power cable is fitted and secures, and our team carefully wires each section to ensure even lighting.
We also use a specific jumping technique between segments to prevent any dimming at the edges of the design. This keeps the sign bright, balanced and long lasting, which is especially important for larger pieces.
Optional Waterproofing
For customers requesting outdoor signs, this is where the waterproofing is applied. We use a liquid plastic sealant that protects the LEDs and wiring from rain, dust and moisture. Once set, the sealant forms a clear protective layer without affecting brightness.
Silicone Tubing and Diffusion
Next comes the silicone tubing, which gives LED neon signs their familiar soft neon style glow. The silicone is flexible, cut to shape and glued securely into position. Unlike may other competitors we also make sure the silicone tubing matches the LED colour instead of using a standard white, this allows the colour to be as vibrant as possible.
This tubing diffuses the light from the LEDs, blending individual points of light into a smooth and continuous beam. It is this process that transforms raw lighting into the polished neon look customers expect.
Step 3: Preparation and Packing
Peeling the Protective Layer
During production, the acrylic board is covered with a protective film to prevent marks. Once the sign is complete, the film is peeled away to reveal a clean and flawless surface.
Cleaning and Polishing
Any glue residue is removed with acetone, and the sign receives its final polish. If small marks appear during manufacturing, they are carefully buffed out so that the sign arrives in perfect condition.
Packing and Shipping
The last stage is packing. Each sign is wrapped securely in bubble wrap and boxed along with its accessories, including the power supply, dimmer, remote or mounting kit. Smaller signs fit into standard sized boxes, while larger ones are placed in custom made packaging built from strong materials.
For multiple sign orders, items may be packed in more than one box, and accessories may be placed separately to ensure safe delivery.
From Workshop to Your Wall
Every Neon Daddy sign goes through this careful and well managed process to ensure it arrives looking incredible and ready to install. From precise cutting to hand finished polishing, each step reflects the craftsmanship and attention to detail that goes into every piece we create.
If you are thinking about designing your own LED neon sign, our team would be delighted to bring your idea to life, one glowing line at a time.
