How Our Tile Is Made

How Our Tile is Made

The process to create these beautiful works involves many steps.

Step 1

First a series of sketches and detail drawings are evolved to develop the basic design.

Step 2

Then the initial sculpture is executed in clay on a piece of clear glass 14% larger than the finished product to allow for shrinkage of the porcelain in the kiln.

Step 3

From this first clay sculpture a waste mold ........

Step 4

.......and then a plaster model is made.

Step 5

It is the plaster model which is then heavily reworked by Ron to add the extreme detail and lifelike character of the piece.

Step 6 & 7

Once he is satisfied with the work, the next set of molds are made called, "block molds". At this point, several casts are made in the block mold to identify any trouble spots which may need to be corrected in the plaster model. If the first casts emerge and fire properly then the "case" mold is produced. This is the master mold from which all of the production molds are made.

Step 8

The production molds are made of plaster, so when the liquid porcelain, called "slip", is poured in......

Step 9

........the mold acts like a sponge and draws the water out of the slip leaving a fragile but handleable clay piece called, "greenware".

Step 10

The greenware is air dried further, the mold seams cleaned, the tile is hand polished and any imperfections are corrected.

Step 11

The tile are then loaded into the kiln and fired to 2300 degrees F. Once cooled they are ready to be china painted.

Step 12

The process of decorating porcelain is known as "china painting". This involves the meticulous mixing and application of turpentine, balsam oil and special oxides which turn the desired colors when fired to a temperature of 1400° F.

Once fired, the decorating is a permanent integral part of each finished piece.

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Step 1 First a series of sketches and detail drawings are evolved to develop the basic design.	Step 2 Then the initial sculpture is executed in clay on a piece of clear glass 14% larger than the finished product to allow for shrinkage of the porcelain in the kiln.
Step 3 From this first clay sculpture a waste mold ........	Step 4 .......and then a plaster model is made.
Step 5 It is the plaster model which is then heavily reworked by Ron to add the extreme detail and lifelike character of the piece.	Step 6 & 7 Once he is satisfied with the work, the next set of molds are made called, "block molds". At this point, several casts are made in the block mold to identify any trouble spots which may need to be corrected in the plaster model. If the first casts emerge and fire properly then the "case" mold is produced. This is the master mold from which all of the production molds are made.
Step 8 The production molds are made of plaster, so when the liquid porcelain, called "slip", is poured in......	Step 9 ........the mold acts like a sponge and draws the water out of the slip leaving a fragile but handleable clay piece called, "greenware".
Step 10 The greenware is air dried further, the mold seams cleaned, the tile is hand polished and any imperfections are corrected.	Step 11 The tile are then loaded into the kiln and fired to 2300 degrees F. Once cooled they are ready to be china painted.
Step 12 The process of decorating porcelain is known as "china painting". This involves the meticulous mixing and application of turpentine, balsam oil and special oxides which turn the desired colors when fired to a temperature of 1400° F.	Once fired, the decorating is a permanent integral part of each finished piece.