Neon-Inspired 3D Printed LED Sign Final Report part 1

Introduction 

Neon signs have long been emblematic of urban nightlife, advertising, and artistic expression. Their radiant colors and distinctive glow became iconic features of 20th-century streetscapes, particularly in entertainment districts and bustling city centers. From their inception in the early 20th century to their modern reinterpretations through 3D printing and LED technology, neon signs continue to captivate with their luminous allure. Today, with more accessible tools and materials, creators can replicate the visual magic of neon using energy-efficient LEDs and digital fabrication methods. This report explores the rich history of neon signage and provides a behind-the-scenes look on how I created my own project inspired by vintage Americana and comic book pop art. 

Historical Background of Neon Signs 

The concept of neon lighting can be traced back to the 17th century, when French astronomer Jean Picard observed a faint glow in a mercury barometer tube—an early encounter with what would later be understood as gas-discharge light. In 1855, physicist and glassblower Heinrich Geissler took a major step forward by developing the Geissler tube; a sealed glass tube filled with low-pressure gas that emitted colored light when electrified. These tubes fascinated both scientists and the public, laying the groundwork for future innovation in gas-discharge lighting .

The true advent of neon lighting occurred in 1910, when French engineer and chemist Georges Claude demonstrated the first practical neon lamp at the Paris Motor Show. By introducing an electric current into sealed glass tubes containing neon gas, Claude created a brilliant red-orange glow, captivating attendees and marking the beginning of neon signage as both an advertising tool and artistic medium. His invention was quickly commercialized, leading to neon’s expansion into international markets.

In the United States, neon signs took off in the 1920s. The first American neon sign was installed at a Packard car dealership in Los Angeles in 1923, and the effect was mesmerizing – drivers reportedly stopped in the street to stare. Over the next few decades, neon signs became a defining element of American streetscapes, lighting up Times Square, Las Vegas, and countless diners, bars, and motels. Internationally, cities like Tokyo and Hong Kong adopted neon on a massive scale, giving rise to some of the world’s most iconic cityscapes. Although traditional neon saw a decline starting in the late 20th century due to the rise of more efficient LED technology, its aesthetic and cultural significance have endured, fueling a new wave of reinterpretation in digital fabrication and DIY communities.
 

Vintage Coca Cola neon sign

Modern Recreation: 3D Printing Neon-Inspired Signs 

Thanks to advances in 3D printing and LED technology, modern makers can now recreate the visual appeal of traditional neon signs without the need for glass bending, high voltage, or rare gases. Flexible LED filaments—made to mimic the continuous glow of neon—can be embedded into 3D-printed channels, allowing for safe, customizable, and energy-efficient signage that retains the same aesthetic charm. 

As a maker and designer, my goal was to capture the essence of early neon signage and bring it into a modern context. This idea started as a home office decor project, where I wanted to display my gamer tag, “TheGreasyPotato,” in a stylized and visually striking way. I envisioned a piece that combines the nostalgia of mid-century Americana with the bold, graphic sensibility of comic book pop art. The final design is both functional and deeply personal—serving as a display of identity and artistic expression. 

Design and Planning 

The process began with conceptualization. I explored vintage signage, comic book fonts, and 1960s pop art for inspiration. The bold lines, dramatic outlines, and vibrant colors of that era’s design language felt like a perfect match for what I wanted to communicate. 

Using Fusion 360, I developed a 3D model of the sign. I followed a helpful YouTube tutorial that provided a step-by-step process for modeling signs with channels for LED strips. My design included carefully sized grooves to ensure the LED filament would fit snugly, and holes for routing wires and connectors. 

 

For more flexibility, I decided to model each part of the text—each word in “TheGreasyPotato”—as separate components. This not only gave me more control over positioning but also made it easier to print and troubleshoot individual parts if needed. 

I printed a small prototype using black and white PLA filament, chosen to reflect and diffuse the LED light as evenly as possible. I used fine print settings to ensure that the channel walls were clean and wouldn’t interfere with filament placement. 

 

This phase also allowed me to verify scale and structure before committing to the full-size version. I checked tolerances and made slight adjustments to better fit the LED strips. 

In my next report, I’ll cover the full assembly, including LED integration, power supply setup, and mounting the sign for display. 

Small scale size of the 3D model I created

Prototype to test printer settings and overall look of the final design

Pop Art Neon-Inspired LED Sign 

This project is an example of how digital tools can be used to reinterpret traditional aesthetics. My sign combines modern 3D printing methods with the visual language of pop art to create a unique, expressive piece. The stylized text, bold contours, and glowing LED filaments give it the appearance of a classic neon sign—while being safe, customizable, and made entirely at home. 

The sign not only functions as wall decor but also represents a part of my digital identity. As “TheGreasyPotato,” I’ve incorporated my gamer persona into an art object that merges personal branding with nostalgic design cues. It’s a piece that bridges past and present—a tribute to the legacy of neon signs and a celebration of maker culture. 

First iteration of the full size piece

Conclusion 

The evolution of neon signage—from delicate, gas-filled glass tubes to safe and energy-efficient 3D-printed LED displays—illustrates the power of innovation in preserving and reimagining cultural icons. By combining new fabrication tools with creative inspiration, today’s makers can capture the glow and spirit of neon in ways that are more accessible and customizable than ever before. 

Whether it’s for personal expression, business signage, or artistic experimentation, neon-inspired LED signs made with 3D printing are a brilliant way to light up your world with history, personality, and creativity. 

References 

[1] AESDES. (2025, February 26). Main project plans and inspirations. Aesthetics of Design. https://www.aesdes.org/2025/02/26/main-project-plans-and-inspirations-22/ 

[2] AESDES. (2025, March 12). Design preview – Pop art neon-inspired LED sign. Aesthetics of Design. https://www.aesdes.org/2025/03/12/design-preview-pop-art-neon-inspired-led-sign/ 

[3] AESDES. (2025, April 14). Progress on my neon-inspired 3D printed LED sign. Aesthetics of Design. https://www.aesdes.org/2025/04/14/progress-on-my-neon-inspired-3d-printed-led-sign/ 

[4] Moneymaker Photography. (n.d.). A brief history of neon lighting. https://www.moneymakerphotography.com/brief-history-neon-lighting/ 

[5] National Institute of Standards and Technology. (n.d.). Luminous script signs: Origins of the neon sign. https://www.nist.gov/nist-museum/luminous-script-signs-origins-neon-sign 

[6] Preserving the Wildwoods. (n.d.). A brief history of neon signs. https://www.preservingthewildwoods.com/blog/a-brief-history-of-neon-signs 

[7] Sygns. (n.d.). History of neon signs. https://www.sygns.com/blog/history-of-neon-signs/ 

[8] Wikipedia contributors. (2024, March 19). Neon sign. In Wikipedia. https://en.wikipedia.org/wiki/Neon_sign 

[9] Wired. (2012, December 11). Dec. 11, 1910: Neon lights the city of light. https://www.wired.com/2012/12/dec-11-1910-neon-lights-the-city-of-light/ 

[10] Wired. (2016, June 22). Bask in the glow of Hong Kong’s vanishing neon lights. https://www.wired.com/2016/06/bask-glow-hong-kongs-vanishing-neon-lights/ 

[11] YouTube. (2023, April 14). How to make a DIY LED neon sign with 3D printing [Video]. YouTube. https://www.youtube.com/watch?v=Hufr2D_5fVc 

[12] Printables. (n.d.). How to make desktop neon signs (3D printable, battery powered). https://www.printables.com/model/332454-how-to-make-desktop-neon-signs-3d-printable-batter