Much of the hand made tile work we do is custom, and clients are often curious about how the process works. I thought I'd share a behind the scenes look at a custom job we're working on right now, to demystify the process. About two weeks ago a charming couple contacted us, hoping we could help to fulfill a vision they had for a special accent tile to incorporate into the tile floors in their new lakeside home in Ontario. Here is their exquisite home site:
Often, the design process is the most time consuming aspect of a custom job - it's not unusual for us to go back and forth for a few weeks exchanging ideas with the client and refining their vision into a motif that will work on our tiles, then choosing colours, etc. These clients, however, were way ahead of the game. They had already chosen a glaze colour and "feel" from our current line, and they had purchased rights to the artwork they wanted, and even sized and formatted it for us to work with easily! This made it easy for me to get right to work in the studio. My first step was to create an original tile from the artwork provided. Here is my clean workspace with a pristine clay slab waiting for carving:
Often, the design process is the most time consuming aspect of a custom job - it's not unusual for us to go back and forth for a few weeks exchanging ideas with the client and refining their vision into a motif that will work on our tiles, then choosing colours, etc. These clients, however, were way ahead of the game. They had already chosen a glaze colour and "feel" from our current line, and they had purchased rights to the artwork they wanted, and even sized and formatted it for us to work with easily! This made it easy for me to get right to work in the studio. My first step was to create an original tile from the artwork provided. Here is my clean workspace with a pristine clay slab waiting for carving:
First, I transfer the artwork onto the slab. In this case, it was a motif provided by the clients, but often it is an original work I create in response to the clients vision:
Next, I carve the motif into the slab:
Once the original tile is carved, and working quickly before the original dries, Bob mixes up a batch of plaster:
The mold form is set up, and we hold our breath as plaster is poured over my original carving:
The plaster is allowed to set for a few hours, then the original tile is removed and discarded. After several days, the plaster mold is dry and ready for use. Bob cuts a slab the correct size, and carefully hand presses it into the waiting mold.
Excess clay is carefully removed from the tile, and the first tile is removed from the mold! This process is repeated until we have the right number of tiles, then the tiles are off to the drying racks. That's where the tiles for this job are right now. The next step will be bisque firing and glazing... I'll post on that next week!







