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These ceramic bottles were created using “cold polychrome” techniques. The process is as follows:
Creating this bottle has been a challenge.
Numerous tests had to be carried out, as the glass
bottle’s sides are not uniform, the production is
artsanal and the clay has a natural contraction of 10% to 12%” – Carlos Bustos
Preparing the clay.
Placing the clay in the mold.
The clay is placed in 3 molds, necessary to make a 3-piece clay bottle. Plaster molds are used for pressure casting, and the molds must be opened at precisely the right moment, otherwise the pieces will shatter if left in the molds too long. Weather also plays a role, as rain or humidity will slow the process. After molding, each piece is immediately moved to a space suitable for drying.
Firing the pieces.
Attaching the glass bottle.
Each glass bottle is paired with an armor plate, and they are bound together with stucco (a paste of lime and sand, initially soft and malleable which gradually hardens. Stucco was used by the Maya and Aztecs.) Once assembled, you now have a clay bottle, which is sanded by hand, and every part of the bottle is hand detailed. The master craftsman uses his sense of touch, smoothing out the surface’s many peaks and valleys as he applies the finishing touches.
Painting the clay bottle.
Finally, a base coat of acrylic paint is applied to the clay bottle as the final step of the process. It takes about 7 days to make a single clay bottle. The maximum production during these 7 days is 10 bottles. The clay bottle weighs 5.97 lbs.
“Creating this bottle has been a challenge. Numerous tests had to be carried out, as the glass bottle’s sides are not uniform, the production is artisanal and the clay has a natural contraction of 10% to 12%.” –Carlos Bustos