Glass Fusing

What is fusing? Fusing is the process of melting glass together in a kiln at a temperature of about 1485 F. Slumping is heating glass just enough to soften it so it will conform to a shaped mold, about 1210 F.

The Firing Process Fusing and slumping are always done in two separate steps. Both the fusion and slumping cycles take about 22 hours each. The glass must be cooled very slowly in order to reduce stress and avoid thermal shock. Pieces are loaded into the kiln cold, heated, cooled, and removed cold.

Glass Compatibility Since different pieces of glass are being melted together, they must expand and contract at the same rate or they will break as they cool. Special tested compatible fusion glass must be used on all fusion projects. Other glass could crack or devitrify in the kiln. ONLY USE FUSION GLASS ON FUSION PROJECTS!

Decorative Techniques There are literally endless possibilities in fusing glass…enough to have an entire fusing class. Here are some of the easiest and most popular for beginners.

Appliqué Appliqué is cutting pieces of glass to shape, setting the pieces on top, and fusing together. Pieces must be held on with Glas-Tac so piece may be moved into kiln. When fused, pieces will be slightly raised.

Appliqué can be several layers thick. When fused, the glass will sink into the layers beneath it, leaving the appliqué only slightly raised. Different layers do not require separate firings. If gravity holds them in place, they can all go in at once.

Frit Frit is ground glass that is applied to the base. Frit can be sprinkled on or mixed with Glas-Tac and painted on. You must wear a particle mask if using fine or powdered frit.

Frit has a mottled look of spray paint. It’s great for flowers, landscapes, and animals. It’s not so good for fine details.

This one was cool until it was ruined with the sloppy kindergarten writing. Sometimes less is more.

A really amazing artist can “paint” with frit.

Stringers Stringers are long thin pieces of glass shaped like spaghetti. They make stripes when fused to a base. Stringers must be stuck on with Glas-Tac or they’ll roll around on their way into the kiln.

Confetti

Stringers can be bent over a lampworking torch. They must fully contact the base and be stuck on with Glas-Tac.

This dish is made of two layers of clear glass with a full layer of stringers fused on the top without gaps.

Nuggets Nuggets are like half-marbles, rounded with a flat back. Nuggets are easily made by diagonally stacking two ½ inch squares and fusing them on the kiln shelf. They automatically pull into a rounded shape. Nuggets must be made of fusing glass, and are done in a separate step before fusing of your dish.

In order to keep the raised look of the nuggets, your project will need to go in a “tack fire” instead of a full fuse. Don’t put the project back with the regular full fuse projects.

Strips Strips are glass that you cut into long thin pieces. They can be laid out into lacy patterns with voids, or can be sandwiched together to form a solid sheet.

If you want more cylindrical, 3-D strips, lay them on the kiln shelf and fuse them before using them on your project. The tops will automatically round up like the nuggets. Then you can put them together on the base. Like nugggets, they will retain their dimension.

This bowl is made by fusing strips together, then cutting the circle. The bowl is then slumped and polished at the top edge. This takes a great amount of skill and fancy equipment we don’t have. But it is cool.

Project 1: Appliqué Fusion Minimum 4 ½ x 4 ½ inches Minimum 2 layers thick Round, oval, square, or rectangular form Maximum 4 colors Geometric or organic pattern featuring repeated shapes and motifs--No logos, words, pictures, etc. May also include other decorative techniques May be slumped or left flat

Geometric Pattern A geometric pattern includes repeated recognized shapes, such as circles, squares, triangles, etc. Symmetry is not required.

Organic Pattern Organic designs are free- flowing and derived from natural forms. They make use of irregular, curving shapes. Organic patterns should not be symmetrical, but should still be balanced.

“A+” Quality Appliqué Projects These projects show planning and precision in cutting and layout They make good use of color through contrast and limited palettes. They feature repeated shapes.

Not bad, but… Repetition of shapes, but limited use of repetition of pattern (both) Less planning and precision in cutting and layout (both) Less effective use of color through contrast (top) and limited palettes (bottom).

What I don’t want This looks like the artist picked up bunch of pieces from the free box and randomly laid them out on a white base. No craftsmanship, no creativity, no effort. Consequently, no points.

Designs to Inspire You

Appliqué Fusion Procedure Choose mold. Trace top of mold onto design paper and write mold number. Put mold back on shelf. Draw design on paper. Make tag board pattern if necessary for both the appliqué and base. Sign up and buy glass. Cut pattern pieces and two bases. Wash and dry. Stack two base pieces, clear on top. Use Glas-Tac to stick pattern pieces on top. Put project back on fusing table. Put design paper with name and mold in fusing order box.

A note about money… Fusion glass is expensive! It’s about $6-8+ per square foot, and you need two layers, so a 12” square plate will be upwards of $16. Be sure you can afford your project before you start! You will need about $15 for your final project, the stained glass panel. If you don’t have enough (or STILL haven’t paid your fee!), you’ll need to use the 4 ½ inch precut squares ($3.50 for 2 pieces) and the free glass for your appliqué. This will limit your color choices.

Project 2: Copper Inlay A very thin piece of copper is cut out with scissors and sandwiched between two pieces of fusing glass. The kiln heat turns the copper various red shades. Because the copper does not stretch when heated, only minor slumping can be done in areas with the copper inlay.

This 12 x 24” tray by Charleton Glassworks costs $175. They sell these downtown. You could make one for Mom in 20 minutes and be the favorite kid this Christmas!

Procedure for Copper Inlay Choose mold and cut two pieces of fusing glass to fit. The top piece must be clear. Wash and dry. Draw sketch for copper pattern on newsprint. Be sure the size fits a flat area of the mold, since the copper will not stretch to shape like the glass. Transfer pattern to copper by tracing over to dent copper. Cut out with scissors. Flatten copper. Put your name and desired form number on your design sheet. Put project on fusing table and paper into fusing order box.

Copper Inlay Requirements 4.5 x 4.5” 2 layers thick, top layer must be clear Soap dish form Complex, intricate copper cut. Copper cut must be in one piece Copper cut must fit in flat area of slump mold Finished project may be slumped or left flat Inlay project must be ready to fuse by _____.

These don't really meet the assignment criteria, but they’re kind of fun. If you have some extra time….

Have a little scrap left? This plant stake is fused with the copper wires between two layers, which are curled and painted after firing. You could also make sun catchers or Christmas ornaments in this way.

Advanced Techniques