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Tile Process from David Regan Tile
We've received many comments from people who, after ordering their tiles based on pictures from the internet, have been pleasantly surprised when they can see their tiles in person. The imagery, unlike most commercial tile, is not painted on the surface, but is a result of a texture embossed into the surface of the wet clay tile. This texture is very shallow and barely detectable until the tiles are glazed and fired. The glaze, which is fired to an excess of 2300 degrees Fahrenheit, pools in the recesses and recedes from the edges, filling in the embossed surface with varying thicknesses of the single colored glaze. In some areas, the glaze may pool up to 1/8” thick, resulting in a very dark value, while in other areas, it is paper thin, resulting in a lighter value. The resulting tile is smooth and glossy but the underlying texture can still be felt.
Texture is added to the surface of the wet clay tile using a rubber brush.

The first step in the process is the very time consuming process of sculpting the texture into the surface of the wet clay. This texture can be made with various tools such as chisels, pin tools and sponges. The glaze will amplify even the smallest lines, so great care and attention is necessary during this step. When finished, a plaster mold is made from the original tile into which multiple tiles can be pressed, all perfectly matching the original.

The tile is then glazed with one of our five glaze colors.  The glazes are mixed right here in the tile studio and are our own secret formulas. The glazes are mixed to an exact viscosity, which when ladled onto the surface, fills in and temporarily obscures the embossed texture underneath.  The excess glaze which drips over the side is sponged off to prevent the melting glaze from sticking to the kiln shelf.

After firing, the finished tile reveals the melted blue glaze, which has pooled in the recesses of the texture. The surface is glossy, smooth and easy to clean, but still retains some of the underlying surface undulations.
Glaze is ladled onto the tile, filling in the embossed texture.

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