Understanding Neon Tubes: How They Work, Why They Matter, and How to Repair Them

Neon tubes are THE core component of real neon lighting
Many people see their iconic glow daily without understanding what goes into making them
Behind each glass neon tube is a very specialised craft
This post will cover what neon tubes are, how they function, and how they can be repaired

What Are Neon Tubes?

Neon tubes are glass tubes that are hand-shaped over a flame by a glassbending specialist and filled with gases such as neon or argon
Most often these tubes are bent to form words or letters or other shapes as if on a 2 dimensional plain, however there are occasions when you may find neon pieces that break into the 3rd dimension
Neon tubes are used in signage, art, decor, and commercial lighting
Neon's iconic glow has been part of the fabric of cultural life in many major cities for over a century. It's beauty and impact is unparalleled in the world of illumination.

A neon electrode is joined to either end of a glass neon tube, which allows an electric current to run through it. The electricity then passes through the gas molecules, producing light through a process called gas discharge
Different gas glows different colours; neon glows a bright red/orange while argon glows a dull violet. To make further alterations to colours, coloured glass can be used as well as fluorescent powder that lines the inside of the tube.
A transformer is required to create enough voltage to ignite the gas inside the tubes.

Real neon uses glass tubes, while LED neon uses plastic casings made from extruded petrochemicals
Real neon is longer-lasting, brighter and more energy efficient than LEDs
A real neon sign is made up of individual tubes that can be replaced should they break or malfunction without having to replace the whole sign. LED "neon" signs on the other hand will degrade as a whole even if one part begins to fail, meaning that a whole new sign will be needed to replace it.

Tube breakage or cracks: Often caused by impact, stress over time or exposure to the elements
Fading: Most commonly due to mercury within the tube solidifying. Can be solved easily by rolling the mercury to either of the electrodes.
Excessive buzzing or flickering: Usually related to a faulty transformer or poor wiring

If a neon tube is broken or appears to not be functioning it will be removed to be worked on by a glassbender. If the tube is in good enough condition, it can be rejoined and pumped with new gas to glow as if new. Otherwise the broken piece can be traced and remade from an entirely new tube of glass.
A broken section of a sign can be repaired or replaced without needing to do so to the whole sign. In fact, a sign can still be made to glow while the missing pieces are being serviced
A glassbender will be able to figure out how to best recreate the shape of a broken neon tube by tracing it's outline or by using their intuitive eye for design. Remnants of a broken piece of neon can also be used to figure out what colour it shone before it broke
A neon glassbending expert is absolutely necessary when it comes to anything neon; anyone else simply won't know where to start

Can any color be made with neon tubes?
Functionally, yes! Combining different gases, colours of glass and fluorescent powder can make all sorts of colours.
Are neon tubes safe?
If installed correctly, yes. High tension cables (cables that connect the transformer to the neon tubes) should be encased in conduit and electrodes should be kept covered by rubber sleeves to prevent human contact with live electricity
Can I reuse old neon tubes in a new design?
Of course, however it is not possible to bend a tube that has already been filled with gas and sealed under vacuum.

A real neon tube is a marvel of science and dexterous crafstmanship
Next time your eyes are captivated by the glow of neon, have a think about what has gone into making it the way it is
Furthermore, if you own a business or are running an art project and need something that stands out bright and magnificent and will stand the test of time, don't hestitate to get in contact with Australian Neon Services!