Having done a drawing I make a plaster model. This is an exact replica of the finished piece.
At this stage I decide on the background - what is to surround the piece.
It is often more difficult to achieve perfect harmony between the motif and
its surroundings and I frequently spend longer working on the surroundings than on
the animal itself. It is the chiselled, crystal-like texture that I want to bring out.
An eagle on a cliff works well but an animal moving through the forest is more difficult.
The background to the animal motif must help to create the mood.
The next step is to engrave the body on the plaster model. Then I varnish the model and make a positive cast of it also in plaster. This cast, which is the right way round, is the model for the final iron mould. On this final plaster model I enhance the fine details of the motif before passing it to the iron foundry. In the foundry a sand core is produced and then the iron mould is cast.
We now have a raw mould. The raw mould is also worked on. I use diamond drills, revolving
files and ultrasonic tools to clarify the details of the motif and to polish the parts
requiring a glossy finish. When I am satisfied with the mould it is passed to the glass
workshop where the molten crystal is cast in it. We start by heating the iron mould so that
the difference in temperature between it and the molten crystal is not too severe. A
"gatherer" takes molten glass from the pot using a long iron. Gathering the melt can leave
imperfections in the crystal. Bubbles may develop and these have to be removed. We use a
crystal of a special type which the Swedish Glass Research Institute has helped us to develop.
This is the most costly crystal but it is especially well suited to casting and pressing. A
large piece of this crystal has greater refraction and is smoother and more brilliant. It
treats the light in a special way.
After casting, the glass is annealed in a lehr for 15-20 hours. If it is cooled too quickly
it will crack. After annealing there is a first quality inspection. Glass with imperfections
is thrown out. It is important to get rid of defective pieces before the laborious
post-production work is started. The first stage consists of sandblasting. If I want a
particular area to remain glossy - the stripes on a zebra, for example - I mask them with
silicon which prevents the sharp sand from getting at them. We work with different grades
of cutting sand at various velocities. After sand-blasting the motifs are polished and some
are then sand-blasted again using coarser sand at a higher velocity to increase the whiteness.
Any unevenness on the background and foot of the piece is then ground smooth. First the
piece is ground on a coarse diamond wheel and then on a finer wheel before being polished in
two stages. The second "putty" polishing uses tin oxide which gives a highly polished surface.
The final stage consists of engraving in order to achieve the minutest details of coat,
plumage and eye that are so vital to the impression made by the finished piece.
Beside the effects obtained from making use of relief I also have access to the graphic artist's full range of possibilities. The graphic artist can use every nuance from black to white while I have a scale from polished gloss to coarse matt. The craft process means that each relief is different Many hands and eyes have contributed to the finished object.
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