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How Original Porcelain & Neon Signs Were Made

Before reproduction signs existed, porcelain and neon signs were built to serve a purpose: visibility, durability, and long-term use in harsh environments.

They weren’t decorative objects in the modern sense. They were working signage—designed to hang outdoors, survive weather, and represent major brands for decades at a time. The way they were made reflects that.

Understanding how original signs were produced explains why so many modern reproductions feel wrong, even when the design looks close.

How Original Porcelain Signs Were Made

Original porcelain enamel signs were not painted and they were not printed.

They were made from heavy steel, typically far thicker than what is used today. Steel blanks were cut, punched for mounting holes, and in many cases hand-rolled at the edges to add strength and rigidity.

Once formed, the steel was coated with ground glass enamel—a powdered glass mixture that was applied in layers. Each color was fired separately in a kiln at extremely high temperatures, causing the enamel to fuse permanently to the steel surface.

This process was repeated color by color.

The result was a surface that:

  • Had depth rather than a flat finish
  • Was resistant to fading, scratching, and weather
  • Became part of the steel itself, not a coating on top

Because each firing introduced slight variations, no two signs were ever perfectly identical. That subtle inconsistency is part of what gives original porcelain signs their character.

This was not a fast or inexpensive process. It required specialized equipment, skilled labor, and time. But it produced signs that were meant to last decades—and many still exist today because of it.

How Original Neon Signs Were Made

Neon signs were never LED-based, molded, or pre-assembled.

They were built by hand.

Real neon signs used real glass tubing, heated and bent by skilled craftsmen who shaped each tube over an open flame. The glass was formed to match the design precisely, then filled with noble gases such as neon or argon to produce specific colors when electrified.

Each tube was:

  • Hand-bent
  • Individually processed
  • Sealed and tested

These tubes were mounted onto steel housings or porcelain-backed cans using insulated supports. High-voltage transformers powered the sign, producing the soft, continuous glow neon is known for.

Unlike modern alternatives, neon signs were designed to be serviceable. Tubes could be repaired or replaced, transformers could be swapped, and the sign itself was built to remain structurally sound over time.

That’s why many original neon signs from the mid-20th century are still operational—or can be restored—today. That’s the idea leading to the meticulous, time-intensive, and highly skilled craftsmanship in How Real Neon Signs Are Made behind the scenes at Porcelain Advertising.

Why Materials and Process Matter

When you compare original signs to modern reproductions, the differences usually come down to materials and shortcuts, not design.

Thin metal replaces heavy steel.

Vinyl or printed surfaces replace kiln-fired enamel.

Plastic LED tubing replaces hand-blown glass.

Those changes reduce cost and speed up production, but they also change:

  • Weight
  • Depth
  • Light quality
  • Longevity

Original signs weren’t designed to look good briefly. They were designed to represent brands permanently.

That intent is built into how they were made.

How This History Informs Modern Reproductions

Accurate reproductions don’t start with artwork alone. They start with understanding the original construction.

When authentic craftsmen follow the same principles—heavy steel, real porcelain enamel, real glass neon—the result feels right because it’s built on the same foundation.

When those principles are ignored, the difference may not be obvious in photos, but it becomes clear the moment the sign is handled, hung, or seen in person.

The originals set the standard.

Everything else is measured against that.

Related Reading

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Each piece is handcrafted by skilled artisans, not mass-produced overseas. Quality like this doesn’t come off an assembly line.

Authentic Materials

You won’t find acrylic, stickers, or fake glow here. This is real neon—heavy, durable, and made to last a lifetime.

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FAQ ANSWERS & QUESTIONS

ABOUT OUR SIGNS

How are your signs made?

Our signs are crafted using real porcelain enamel on heavy-gauge steel, kiln-fired layer-by-layer - Just like the originals. No stickers. No cheap shortcuts.

Do you really use porcelain?

Yes! Unlike most reproductions, our signs are made with real porcelain enamel, which means they won't fade, peel, or scratch like printed metal signs or acrylic.

Where are your signs made?

All our signs are proudly made in the USA using traditional methods that honor the craftsmanship of the past.

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