Short answer: Most LED neon signs are built on 1/4 in. clear or black acrylic, cut to follow the outline of the design about 1 in. out from the tubing. The board gets small holes for clips or zip ties every 3 to 4 in. along the flex, holes for the wire to pass through, and four mounting holes for standoffs. Send us the flex path as a drawing and we cut the outline and holes together.

Clear or black?

Clear is the most popular choice by far. With the sign off, the board almost disappears and the wall shows through; with it on, the glow spills onto the wall behind it. It suits homes, weddings, cafés, and anywhere the wall is part of the look.

Black hides the wiring, clips, and the back of the flex completely, and makes the colors look more saturated, especially in daylight. It's the better choice for busy walls, windows (where the back would otherwise be seen from outside), and bar or gaming setups where the sign needs to pop.

Frosted, white, and mirror boards are possible too, but frosted and white catch the light and glow themselves, which softens the neon effect. Try a scrap first if you're unsure.

What size and thickness to choose

  • 1/8 in.: small signs under about 12 in. wide that will hang flat on a wall with tape or two screws. It flexes, so not for anything larger.
  • 1/4 in. (about 6 mm): the standard for signs 12 to 48 in. wide. Stiff enough to stay flat, and the holes for clips hold well.
  • 3/8 in.: very large signs, or hanging signs that may get bumped.

Leave about 1 in. of board beyond the outermost tubing. Less and the edges look cramped; more and the board starts to read as a panel rather than an outline.

Cut to the outline or a rectangle?

A contour-cut board follows the shape of the lettering or artwork, like a cookie cutter offset around the design. It's the look of a professionally made neon sign and makes clear boards almost invisible. A rectangle or rounded rectangle is simpler, cheaper, and works well with text-heavy signs or when you want a defined panel. Cut-to-outline boards are priced from your drawing: upload it and the price appears instantly.

Holes, channels, and wiring

This is where a good backboard file makes the build easy:

  • Clip or tie holes: pairs of small holes (about 3/16 in.) on each side of the flex path every 3 to 4 in., so a zip tie or wire wraps over the tubing. Tighter spacing on curves.
  • Pass-through holes: where the flex dives behind the board to jump between letters, or where the power lead exits. Size them for the flex end cap, usually 3/8 to 1/2 in.
  • Engraved guide lines: a light engraved line along the flex path shows exactly where to lay the tubing. Some builders engrave a shallow channel so the flex sits partly recessed and stays put.
  • Mounting holes: four near the corners for standoffs, or two near the top for hanging chain.

Tip: draw the flex path as a single centerline on its own layer, and put cut lines, holes, and engraving on separate layers. Our guide to preparing a file for laser cutting covers layers, units, and offsets.

How we make it

We laser-cut 1/4 in. backboards in one pass, outline, holes, and engraving together, so everything lines up with your flex path. The laser leaves the cut edges glossy, which matters on clear boards because the edges catch the glow. Boards over 1/2 in. thick are CNC routed instead; see laser cutting acrylic.

Design tips

  • Check the minimum bend radius of your flex and keep curves in your drawing wider than it.
  • Plan where the power cable will run before you place mounting holes, so it doesn't cross a standoff.
  • Keep any hole at least 1/4 in. from the board edge.
  • LED neon runs warm, not hot, so acrylic is a good match; still, keep transformers and drivers off the board itself.

Questions

How do I attach LED neon flex to acrylic?

Clear plastic clips screwed through the board, zip ties or wire through pairs of holes, or mounting tracks glued down with clear silicone. Holes and clips are the most secure and the easiest to repair.

Can an acrylic neon sign go outside?

The acrylic can, but most LED flex and power supplies sold for indoor signs aren't rated for outdoor use. Check the ratings on your flex and power supply first.

What if I only have a sketch of the sign?

Tell us about it on the make-it-in-acrylic page with the size and the words or artwork. We can help turn it into a cut file.