Going through a similar process from design to completion, a small kitchen backsplash is created for clients in Florida. However, as this project did not require multiple tile sets, no molds were made.
After creating the clay slab at a specific size and thickness, the design is transferred onto the surface.
The entire design is rough carved, determining the high and low areas of relief.
All details are carved, formed and smoothed, except those in the deepest background areas.
The background patterns are added...
…Then carved to a certain stage.
The last step consists of lighter carving and smoothing to finish the design.
The completed, full motif.
Individual tiles are created by sectioning the slab into a predetermined number of pieces.
As the tiles dry they are checked for fit, since concave surfaces get smaller; these areas are sanded slightly to allow the tiles to nest correctly. Once completely dry, they are ready for firing.
Tiles in the kiln resting on a material called grog. This acts like ball bearings, allowing the tiles to shrink without friction as they are fired.
The finished tile set, with its unique glaze application that further highlights the relief.