I've made two neon signs. I'm not an expert, but I did learn a lot about the craft, and how that relates to the article.
All neon signs are made by hand. Including those "mass produced" beer signs - they might have made some kind of jig to help, but still all handmade. The process, greatly simplified, typically works like this:
- Design is sketched, by hand, on sheets of butcher's paper,
- Tubes are headed in different types of burners, and bent and joined according to the design and the creator's skill,
- The design is tested in various ways,
- The design is evacuated, with gas(es) and optionally other substances (elemental mercury, sometimes) then added back,
- electrodes installed (involves melting and joining glass),
- The design is then mounted on something, carefully. All that glass gets heavy, and things need to stay rigid,
- Finally, transformers are wired, and the design is lit up.
This is one of my two signs: https://imgur.com/a/ya5L7r2. The overall design is 4' x 4', and weights around 30-40lbs, including the plexi backing. I have no idea how I'll ever move it. It took me ~100 hours to do the entire thing (someone good could have done it in less than 20 hours). It uses, I believe, argon plus some mercury to give it a white/blue color.
The diminishing demand for neon signage is shrinking the ecosystem. Less neon craftspeople, less sources of the tubing, vanishing materials distribution. One instructor told me that "LEDs killed my business". All of this means that getting neon made is super expensive. Simply put, there are no unskilled labor stages. There is no technical innovation. I used Inkscape for my design sketch, and all of the old hands thought it was magic.
LEDs have many advantages. They're cheaper, the signs weigh less, they do not need rigidity, and they can be created with a lot of much cheaper labor.
Nonetheless, you'll never get that quality of light from an LED. Neon has a quality that is impossible to duplicate - a warm, liquid quality. Subjectivity aside, neon signage retains a singular practical advantage. If you need to fix or alter a neon sign, it'll always have the same light quality if you use the same gases and other materials. Need to replace a letter from your LED sign years down the line? It isn't going to match. You'll never find the same exact LEDs ever again.