Commissioned by Electrolight Sydney we were asked to make a quantity of glass forms for three custom designed lighting solutions. The extensive refurbishment was to occupy three separate spaces within the Gateway Plaza, Circular Quay. The forms required impeccable precision to facilitate their installation into the specified manufactured fixtures.
One of the greatest challenges was the quantity and scale of the forms. Physically hot glass equipment is only so big and human capacity to manage the material only so much. To manage the quantity we decided to make a series of moulds, but firstly we needed to make the patterns, or positives. Josh threw the forms on the ceramic wheel, but how do you achieve such accuracy?
Now the positive was made Josh began the process of making 2 part moulds for each form, six moulds in total. The moulds needed to register perfectly, be absolutely symmetrical (no undercuts) and be full of 'airs' to facilitate the hot glass process.
I then travelled to Canberra Glassworks to blow the forms. Working with a highly skilled team of four in total we embarked on the job of blowing the quantity order.
We dominated the hot and cold shop once the forms started to appear from the lehrs. Each piece needed to be cut on the diamond saw, ground to a satin finish and most of the forms required a hole drilled in the bottom to facilitate the fixture.
The Bronze Milk Crate was created for Bespoke, an exhibition shown in conjunction with design exposition DEN Fair. 'DEN brings together the most inspiring collaborative of talent and brand names under one roof to create an unprecedented platform for the interior & design industry to connect and do business'.
Focusing on the brief from Bespoke directors; Respond to ‘the humble box’ we conceived the idea of celebrating the iconic milk crate. Impeccably designed for practicality, longevity, simplicity & user friendly the milk crate became our creative foundation. Understanding that Bespoke is a platform to display skill, craftsmanship and boundary pushing of your chosen material, we decided to work collaboratively towards the exhibit. The form was appropriately challenging with thin linear grids to negotiate, proving a very complicated execution of translating one material into another.
Once we decided upon a stylish crate we cut one side, made a rubber negative with plaster casing, we then cast four sides separately in wax to later construct them into the four sided crate seen here. This crate was then sprued with airs and given runners so that the mould could breathe and allow the bronze to flow.
It worked a treat, the material managed to find every thin linear section of the crate, the detail exquisite, now to polish her up and give a light patina.
We were commissioned by the Urban Perveyor Group to create life size Spanish mission bells for their new bar/restaurant El Camino. These large majestic bells originally cast in bronze stand approximately 700mm high and 750mm wide at their largest girth, the bells are often decorated with text, religious icons, ribbing and beautifully decorated eyelets that allow them to be suspended high within the church tower.
The client wanted a direct replica including an age old patina. We decided that we needed a pattern, a positive, from their we could make a rubber negative with casing and then produce the four positives from plaster. Plaster was chosen as a strong, malleable material, light in weight and posessing a surface which would respond well to colouration.
Josh created a coil style vessel 720mm diameter and rising to 700mm in height. As he coiled he smoothed and shaped the form to replicate the bell. Once the foundation was made we moulded clay crosses and hand cut letters in Spanish font to spell El Camino. Now the positive was finished it was time to create a rubber negative with plaster casing.
Plaster positives were then cast, reinforced and coloured to look like bronze.