The process of converting a concept into an ornament consists of three phases: Design, Mold Making, and Production.

Most designs begin life as a photo, drawing, or sketch. Using the photo as a reference, John “sculpts” a virtual ornament using 3D modeling software.  Once completed, a master is created from UV resin.  This master is sanded and cleaned, in preparation for mold making.

A mold is a container into which pewter is poured. To make a mold, the “master”  is encased in raw silicone.  The silicone is then pressurized and heated.  The result is a hardened block of cured silicone, having a cavity with a perfect impression of the master.  The master is then removed.  Paths (for pewter to enter and air to exit) are cut into the mold.  The mold is then tested and fine-tuned for reliability.  

Finally, it’s time to make an ornament.  The mold is placed into a casting machine that holds the mold tight and spins at a high rate of speed.  Pewter is poured into the mold and solidifies in a minute or so, producing a “rough casting.”  For the finishing touches, the rough casting is filed, sanded, wire brushed, aged, and cleaned.  Add a little string and the ornament is complete.