How it's Made
The Process:
- Designing - I create a design for the piece either by hand or using specialized software. Then print the design and make two copies of the pattern – one that is placed on the glass for cutting the pieces out and the other that is used to set all the cut pieces on to make sure everything fits correctly.
- Cutting Glass – most pieces of glass are hand cut. Only pieces that are impossible to cut by hand are cut with a glass saw.
- Grinding – rough edges are ground smooth and final shaping is done to ensure that pieces fit correctly without gaps – it’s like putting a puzzle together.
- Copper Foiling or Leading – foil is wrapped around each piece, and it is burnished to assure the foil adheres tightly. The foil is necessary for the solder to have something to adhere to. This method is referred to as the Tiffany method. The alternative method is to use lead came between each piece and this is done on larger panels or as a border around some suncatchers.
- Soldering – flux is applied to the foil and a hot iron is used to melt the solder. Most of my pieces are made with 60/40 solder (60% tin, 40% lead) – the use of lead in stained glass is not harmful. Lead is only dangerous if eaten or inhaled, but it is always a good idea to wash your hands after handling as a precaution. The majority of stained glass is made this way. Lead-free solder is used on jewelry pieces.
- Finishing – I wash and polish each piece before applying either black or copper patina. Occasionally, a piece looks better if it is left silver. This decision depends on the choice of glass and the desired look of the finished piece. The finished piece is then waxed and polished.
The metals and finishes used in stained glass tend to naturally oxidize over time. When your stained glass piece is finished, it's waxed to slow down this process, but this is a natural occurrence that will happen to stained glass. Periodically applying wax helps to maintain the look of your piece.