The Tile Making Process
{a brief description of how we spend our days}
Working in the tradition of Henry Mercer of the Moravian Pottery and Tile Works and the Arts and Crafts Movement, Blue Willow Studio produces strictly hand-made and hand-glazed ceramic tiles and miscellaneous pottery. We use a few techniques to create and decorate our tiles, briefly described below. For more in depth tutorials exploring our processes, please see the Get Your Hands Dirty section of our blog, Playing with Mud and Fire.
Alphabet Knot Tiles
Press Mold Tiles
Many of our tiles (like our Alphabet Knot Tiles) are created using press molds. This allows us to produce multiple copies of our tiles, alter colors and finishes, and offer an affordable, hand-made tile option to our customers. All of our designs are original, and we make all our own press molds in the studio. You can read more about the mold making process in our blog post Meet My Friend, Plaster: Making a Plaster Press Mold.
Many of our tiles (like our Alphabet Knot Tiles) are created using press molds. This allows us to produce multiple copies of our tiles, alter colors and finishes, and offer an affordable, hand-made tile option to our customers. All of our designs are original, and we make all our own press molds in the studio. You can read more about the mold making process in our blog post Meet My Friend, Plaster: Making a Plaster Press Mold.
A press mold for a ceramic tile (Knot Number 0).
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Press Molds from a Master Tile
Some of our press molds are created from a master tile. In this technique, the tile design is carved and sculpted from a slab of clay. Using small metal tools, the process of carving the tile usually takes many hours to complete. The master tile is then molded in plaster, creating the press mold from which replicas of the tile can be made. Learn more about the Master Tile process in our blog post Carving Clay: Celtic Knot Numbers & Alphabet (Part 2).
Some of our press molds are created from a master tile. In this technique, the tile design is carved and sculpted from a slab of clay. Using small metal tools, the process of carving the tile usually takes many hours to complete. The master tile is then molded in plaster, creating the press mold from which replicas of the tile can be made. Learn more about the Master Tile process in our blog post Carving Clay: Celtic Knot Numbers & Alphabet (Part 2).
Carving a master tile from a slab of clay. Once complete, the master tile will be cast in plaster to create a mold.
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Press Molds from Plaster
Some of our press molds are created directly from plaster. In this technique, a blank tile is molded in plaster. The tile design is carved directly into the plaster tile blank, creating the press mold from which duplicates are created. Learn more about the Plaster Carving process in our blog post Carving Plaster: Celtic Knot Numbers & Alphabet (Part 1).
Some of our press molds are created directly from plaster. In this technique, a blank tile is molded in plaster. The tile design is carved directly into the plaster tile blank, creating the press mold from which duplicates are created. Learn more about the Plaster Carving process in our blog post Carving Plaster: Celtic Knot Numbers & Alphabet (Part 1).
Carving a tile design into a plaster mold to create a press mold.
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Using the Press Mold
Once the tile mold has been made, a slab of clay is pressed into the cavity of the mold. We use a rubber mallet to generate enough force to ensure that the clay fills the entire pattern of the tile. The plaster of the mold absorbs some of the moisture in the clay, and within a few minutes, the clay can be removed from the press mold.
Once the tile mold has been made, a slab of clay is pressed into the cavity of the mold. We use a rubber mallet to generate enough force to ensure that the clay fills the entire pattern of the tile. The plaster of the mold absorbs some of the moisture in the clay, and within a few minutes, the clay can be removed from the press mold.
Clay pressed into the cavity of the tile press mold.
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Using a rubber mallet to press clay into a press mold, forming a ceramic tile.
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Individually Carved Tiles
Some of our tiles (see our Carved Tile section) are individually carved, and are therefore not pressed from molds. These tiles are one-off creations, formed from a single slab of clay with the design meticulously hand-carved into the surface of the tile. Each of these tiles takes hours to days to complete.
Some of our tiles (see our Carved Tile section) are individually carved, and are therefore not pressed from molds. These tiles are one-off creations, formed from a single slab of clay with the design meticulously hand-carved into the surface of the tile. Each of these tiles takes hours to days to complete.
Individually hand-carved and hand-glazed tile: Tree of Life Carved Oak Knot.
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Sgraffito Tiles
Sgraffito is a decoration technique dating back centuries, and is another process that does not involve the use of press molds. After a blank tile is formed from a single slab of clay, a layer of colored underglaze or slip is brushed onto the surface of the tile. The underglaze or slip is then carved away in a design so that the original contrasting clay color is visible. Like the individually carved tiles, sgraffito is also a time consuming technique, and complex designs (like the ones on our sgraffito plates), can take tens of hours to complete. See more about the sgraffito technique in our blog post Sgraffito Plates and Such, Part 2: My Experiments.
Sgraffito is a decoration technique dating back centuries, and is another process that does not involve the use of press molds. After a blank tile is formed from a single slab of clay, a layer of colored underglaze or slip is brushed onto the surface of the tile. The underglaze or slip is then carved away in a design so that the original contrasting clay color is visible. Like the individually carved tiles, sgraffito is also a time consuming technique, and complex designs (like the ones on our sgraffito plates), can take tens of hours to complete. See more about the sgraffito technique in our blog post Sgraffito Plates and Such, Part 2: My Experiments.
Porcelain plate decorated using the sgraffito technique
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Leaf Impression Tiles
Some of the designs on our tiles, such as our leaf impression coaster sets, are created using real leaves. A blank tile is formed from a slab of clay. A leaf is then impressed into the soft clay using a roller. When the leaf is removed, the veins of the leaf leave an impression in the clay that can later be emphasized using underglazes and glazes during the glazing process. For a tutorial about making leaf impression ornaments, see our blog post A Project for Autumn: Leaf Ornaments.
Some of the designs on our tiles, such as our leaf impression coaster sets, are created using real leaves. A blank tile is formed from a slab of clay. A leaf is then impressed into the soft clay using a roller. When the leaf is removed, the veins of the leaf leave an impression in the clay that can later be emphasized using underglazes and glazes during the glazing process. For a tutorial about making leaf impression ornaments, see our blog post A Project for Autumn: Leaf Ornaments.
Evergreen Coaster set, featuring leaf impressions from evergreen plants.
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Drying
After creating the tile either using a press mold, the carving technique or the sgraffito technique, the tile is placed between two pieces of drywall to dry. The drywall wicks some of the moisture from the tiles, helps to stabilize the humidity levels around the tile, and keeps the tiles flat during drying. Drying time varies on ambient temperature and humidity, but it usually takes a couple weeks for a tile to dry completely.
After creating the tile either using a press mold, the carving technique or the sgraffito technique, the tile is placed between two pieces of drywall to dry. The drywall wicks some of the moisture from the tiles, helps to stabilize the humidity levels around the tile, and keeps the tiles flat during drying. Drying time varies on ambient temperature and humidity, but it usually takes a couple weeks for a tile to dry completely.
Clay tiles drying on a sheet of drywall.
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Bisque Firing
Once the tiles are dry, they are fired in a kiln two times. The first firing is called the bisque firing, where the tiles are heated to around 1915oF. This solidifies the clay, making it sturdier so that glazes can be applied without fear of damaging the tile. The bisque firing itself takes about 12 hours to complete, with a kiln cooling time of 24 hours before the tiles can be safely removed.
Once the tiles are dry, they are fired in a kiln two times. The first firing is called the bisque firing, where the tiles are heated to around 1915oF. This solidifies the clay, making it sturdier so that glazes can be applied without fear of damaging the tile. The bisque firing itself takes about 12 hours to complete, with a kiln cooling time of 24 hours before the tiles can be safely removed.
Tiles that have been bisque fired.
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Glazing
All of our glazing is done by hand using paint brushes. Our single color tiles (like our Butterfly Knot Tile) take the least amount of time to glaze, while our more detailed, multicolored tiles (like the Carved Sunflower Tile) can take many hours to glaze.
All of our glazing is done by hand using paint brushes. Our single color tiles (like our Butterfly Knot Tile) take the least amount of time to glaze, while our more detailed, multicolored tiles (like the Carved Sunflower Tile) can take many hours to glaze.
Butterfly Knot Tile
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Carved Sunflower Tile
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Glaze Firing
After the tile is glazed, it is once again fired in the kiln, this time to around 2232oF. At this temperature, the stoneware clay that we use becomes vitrified, and has a very low porosity, ensuring its strength and durability. The Glaze firing takes around 15 hours to complete, with a kiln cooling time of 24-36 hours before the finished tiles can be safely removed.
After the tile is glazed, it is once again fired in the kiln, this time to around 2232oF. At this temperature, the stoneware clay that we use becomes vitrified, and has a very low porosity, ensuring its strength and durability. The Glaze firing takes around 15 hours to complete, with a kiln cooling time of 24-36 hours before the finished tiles can be safely removed.
Sgraffito tiles waiting to be unloaded from the kiln after a glaze firing.
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