The Manufacturing Stained Glass
Modern Techniques allow glass to be manufactured to very high standards. This allows creation of items like Graded Seals, Multi-Pin Bases / Stems, Cathode Ray Tube Envelopes, Ultra High Vacuum Viewports and Photomultiplier Envelopes, where the glass is threated to suit the environments that the products will work in. These advanced glass products are manufactured by Moores Glass. Moores Glass is a leader in glass manufacturing and has been exporting glass all over the world for over 40 years.
- First a diagram or design is required to full scale, with details and features included, with notations, specifications and other comments included. Typically the design comes on a single sheet of paper and is laid out on a work surface.
- Coloured glass is then selected which matches the exact specification of the design with consideration given to its position and function of the window (this will dictate how thick/ strong the piece should be). The glass is cut to shape with a glass cutter and curves can be nipped ('grozed') with a specialist pliers.
- Further design is added in a mixture of black or brown metal oxides and powdered glass. It is watered down and painted onto the glass. Solid lines are painted thickly and thin washes are applied and left to dry, then flecked with a badger-hair brush for finer details and shading.
- The painted glass is then fired to fuse the paint to the glass and then left to cool slowly the kiln to relieve the strains created in the glass by firing.
- Cast bars of lead are cut and squeezed through a lead mill, electrically powered or hand cranked, to the approximate shapes and lengths required
- The glass and lead are then assembled on the work table, and the lead is finely cut and bent to fit each piece of glass.
- When a panel is complete, each joint is soldered and the whole window is painted with mastic, brushed hard into all the joints, to seal and weatherproof it.