The Process of Making a New Tile
After the original design is finished, a copy of the sketch is enlarged to around 114% in order to allow for the shrinkage that takes place during drying and firing. For this dimensional tile, a clay model is made using both an additive and subtractive sculpting process.
When the clay model is finished, a plaster mold is poured. The original model is carefully dug out of the plaster after the plaster is set. Sadly, the model is usually destroyed during this phase. The plaster mold is allowed to dry. From the mold, new tiles are cast by pressing wet clay into the mold. The dry plaster naturally pulls moisture from the clay. When the clay starts to pull away from the plaster (much like a baked cake pulls away from the pan when it is done), the tile is removed and left to slowly dry.
Once dry, the clay is bisque fired. The tile is then glazed and fired again.
When the clay model is finished, a plaster mold is poured. The original model is carefully dug out of the plaster after the plaster is set. Sadly, the model is usually destroyed during this phase. The plaster mold is allowed to dry. From the mold, new tiles are cast by pressing wet clay into the mold. The dry plaster naturally pulls moisture from the clay. When the clay starts to pull away from the plaster (much like a baked cake pulls away from the pan when it is done), the tile is removed and left to slowly dry.
Once dry, the clay is bisque fired. The tile is then glazed and fired again.
A photograph of the original drawing.
Phase one of the clay model.
Phase two of the clay model.
The finished clay model, placed in a waterproof box. This photo was taken just before the plaster was poured into the box.
The finished plaster mold. This photo was taken after the model was dug out and the mold was dried.
The glazed tile before it was fired.
Glazing is always a challenge.