Tile Making Process

Concept Development
and Modeling

Mold Making
and Tile Pressing

Firing, Glazing
and, Well... Firing

Concept development for custom architectural tile begins with inspiration. During this phase, multiple design variations are explored, refined and evaluated to arrive at an optimal working design. Each selected concept is then modeled in clay with meticulous attention to detail, ensuring proper relief depth and the elimination of undercuts for successful production.

Tile layouts may include both decorative accent tiles and coordinating field tiles, allowing for seamless integration into architectural installations while maintaining visual harmony.

Once the original clay tile model is complete, a rubber master mold and/or plaster production molds are created to accurately replicate the design and enable reproduction. After the plaster cures for a week or longer, each tile is hand cast by compressing moist clay into the mold cavity.

Once released from the mold, any flaws or missing details are corrected, after which the hand-pressed tiles are slowly and carefully dried over several days. This controlled drying process is essential to prevent cracking, warping and distortion—ensuring structural integrity and long-term durability prior to firing.

Underglazes may be applied to handmade tiles either before or after the bisque firing, depending on the desired surface effect. Once the kiln and tiles have cooled to room temperature, two or more layers of glaze are carefully applied to each tile.

The tiles are then vitrified in a second kiln firing exceeding 2,000°F, producing a strong, non-porous ceramic surface suitable for architectural installation. Iridescent overglazes require a third firing to achieve their distinctive finish. As with all handcrafted art tile, each piece exhibits natural variations and subtle irregularities characteristic of handmade artistry.