The process of manufacture depends on the shape to be obtained. A plain
circular teacup may be cast on a potter's wheel of the ancient kind.
When it is partly dried in a mould, it is turned on a lathe and trimmed;
then the handle, which has been moulded, is affixed with a touch of the
'slip'--the porcelain paste in a state of dilution is the cement used in
all such situations--and the piece is ready for the fire. A plate or
saucer, however, is made by flat pressing; a piece of clay like a
pancake is laid on the mould, which is set revolving on a wheel; the
deft fingers of the workmen press the clay to the proper shape, and it
is then dried. But the elaborate ornamental pieces of graceful design
are made in moulds, and for this process the clay is used in the thin or
'slip' state. The moulds are pressed together, the slip is poured into
them through a hole in one side, and when the moisture has been absorbed
by the plaster moulds sufficiently, the piece is taken out. It is often
necessary, in making a large or complicated piece, to have as many as
twenty or thirty castings. In moulding a figure, for instance, the legs
and arms and hands, even the thumbs in many cases, are cast separately,
and with many other parts of the design are laid before a workman, who
carefully builds up the complete figure out of the apparent chaos of
parts, affixing each piece to the body with a touch of slip. When these
wares are complete, they have to be fired for the first time; and they
are taken to a kiln, and placed with great care and many precautions in
the grim interior. The contraction of the clay under fire is a matter to
which the designers must give much study; and the change which takes
place during forty hours' fierce firing in the kiln is shown by
contrasting an unburnt piece and a piece of 'biscuit' or burnt ware, and
marking the shrinkage. Your ware must be calculated to shrink only so
much; if it shrink a shade further, the whole process may be spoiled.
There is a loss of twenty-five per cent. sometimes in these kilns, in
spite of the assiduous care of the workmen. When the biscuit ware has
cooled, it is dipped in the glaze, which is a compound of lead and borax
and other materials--virtually a sort of glass--and then it is fired for
sixteen hours in the 'glost oven.' There is no contraction in this
ordeal; but there is a risk none the less from other causes. In fact,
there is the danger of injury every time the ware goes to the fire, and
as the highly decorated pieces have to go to the kiln many times, it may
be inferred that the labour of weeks and even months is sometimes
nullified by an untoward accident in the burning.
Public-domain text, read in full here on John Shaqi.
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