Due to it being hidden, Neon flex/rope is not a necessity but it will give a nicer consistent glow, unlike LED modules which can create “spotting” depending on how they are positioned and how far from the surface you mount the sign.
Foamex is fine but the thickness is important because some still let a certain amount of light through and can cause shadows on the face or the letter/shape return. That said, this can be eliminated if you coat the rear os a dark colour followed by a white to promote the illumination spread of the light. Grey-back adhesive on digital vinyl will help this too.
The picture I have attached is a sign we did for a mobile food trailer. I am showing this picture at this angle because it helps you see the “spotting” better one the face of this sign.
Viewed front on, the sign looked perfectly fine and the customer loved it, but from a critical stand-point, you can see the issue!
These are sperate LED modules behind an acrylic face. The way to reduce or illuminate the spotting would be to increase the amount of LED modules in the sign, which will bring the modules closer together and stop the dark areas. or, keep the same amount of modules but make the depth of the side returns deeper and it will automatically increase the spread of light, again eliminating the dark areas.
hope that made sense! 😀