Beach Glass Fusion - Fused and Cast Art Glass by Sandy Beach
Pot Melt, Casting, Kiln-Pressing

Finished pot melts may be seen on the Sculpture and Bowls pages as well

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Glass in kiln prior to pot melt Pot Melts are ostensibly a way to use up scrap glass: pile the glass into a flower pot or bowl with one or more holes, bring the kiln temp to 1700 F. and let the molten glass drizzle through the hole(s) forming a unique piece of art glass.

Once a glass artist has made a pot melt, however, the process tends to become more complicated as he/she tries to control the process with the color, type and amount of glass as well how many holes in the pot.

Below is my log of my pot melt experiments. While most artist use more opaque glass, I've been working with trying to increase the transparency of of each piece. Most of my pieces are melted into either 12 or 15 inch stainless casting rings. Some are then slumped into bowls or other pieces.

In addition to "classic pot melts", I am including other high temp work like aperture pours, wire melts and castings.

# Date/
Times
Glass Weight & Bowl Result Photos

1

09/17/10

3pm

9am

Clear, Persimmon, Opaque Yellow, Clear Yellow, Clear Amber, Clear Orange, Clear Red, White, Opaque Red


 

3.5 lbs

3 hole bowl

12” casting ring

2 similar multicolor triangles, 1 bright on w/ yellow circle

stringer from bowl left raised spot

appear 1/4” thick


Glass Used in Pot Melt

Pot Melt - Cast Glass
Selected for the Slumpworks Design Gallery

 

2

09/18/10

11:30 am

19+ hours

Mostly clear, some white, trans. Steel blue, sea green, teal, cobalt, med. Green


 

3.5 lbs

1 hole bowl

Note: changed firing schedule to 90 min. ea. At 1700 and 960

12” casting ring

Rather watery blue green clearish. White made it milky. No stringer. Larger popable bubbles...maybe decrease 2nd hold. Fused, then slumped into shallow bowl.

Glass Used in Pot Melt

Pot Melt - Cast Glass

Pot Melt Slumped into Bowl
Selected for the Slumpworks Design Gallery

3

09/21/10

10 am

Mostly clear w/ some opaque red and blue.


 

3.5 lbs

4 hole bowl

Note: changed hold at 960 to 2 hours

12” casting ring

Much darker than expected. Use much less color

 

Eventually slumped into 12" diameter shallow bowl


Glass Used in Pot Melt

Pot Melt - Cast Glass

Detail of Pot Melt


 

4

09/29/10

All clear except two pieces each of yellow and green opaque


 

3.5 lbs

4 hole bowl

back to Slumpy's schedule (pot melt 1)

12” casting ring

Shelf not level; thicker on one side than other, not quite to edge on thin side. Green + yellow = brown


Glass Used in Pot Melt

Pot Melt - Cast Glass
 

5

10/11/10
@ 1pm

Clear w/ 2 small pieces of yellow, 2 small pieces of red, 1 small piece of orange


 

4.5 lbs, 15” casting ring

Using Slumpy's schedule, except increasing 1700 hold to 90 min.

Did not quite fill out ring. Not level. Check all shelves. Bottom shelf not level. Removed. Some bubbles. Go back to Slumpy's schedule, even for larger pieces.

Glass Used in Pot Melt

Pot Melt - Cast Glass

6

10/12/10

10:30 am

Layered clear, 1 2x2 piece of cobalt in center, 3 1x1 yellow, 3 1x1 greens around edge

4+ pounds

1 hole bowl

layered

15”ring

Did not fill ring, washed out barely blue overall with light brown “tree rings” .

Some bubbles around edges...try Slumpy's 60 min. hold not 75.

Glass Used in Pot Melt
 

Pot Melt - Cast Glass

Detail of Pot Melt


Pot Melt Draped into Vase
Selected for the Slumpworks Design Gallery

7

10/18/10

7:30 am

Clear, 3 1x1 red, orange, 4 yellow

5 pounds stacked vertically in new (Stan) 9 small hole bowl. Also trying Hotline primer.

15” ring

Pattern like pie pieces. Barely filled ring, used 5 lb glass for good piece. Could use a bit more color. Few bubbles, no stalagtites. Hotline primer sticks worse than regular.


Glass Used in Pot Melt

Pot Melt - Cast Glass
Selected for the 2011 Slumpworks Design Gallery

Detail of Pot Melt
 

8

10/30/10

Clear, dark blue, light blue, white opaque's, blue green translucent.


 

3.5 lb+ 4 hole pot, stacked vertically, more color than usual (after large bridge broke trying to use 5.5# for 15” ring)

Nice colors, mostly blue, fairly transparent, quite thick, not too many bubbles.

Glass Used in Pot Melt

Pot Melt - Cast Glass

Detail of Pot Melt
 

9

11/15/10
1pm
8am

Clear, multiple shades of cobalt and light opaque and transparent blues w/ some white. Stacked on edge

5 lb
5 hole Stan pot
15” ring

Kiln not level, ring not filled


Glass Used in Pot Melt
Result broken for melt 12

10

11/15/10
1pm
8am

Flat layered transparent purple, white, clear, opaque red, clear, opaque mid blue

3.5 lb
4 hole pot,
12” ring

Kiln not level, ring not filled. Probably too dark anyway.

LEVEL SHELVES!!


Glass Used in Pot Melt

Pot Melt - Cast Glass

11

11/16/10
9am
7am

Clear, multiple shades of cobalt and light opaque and transparent blues w/ some white and a little green. Stacked on edge

5 lb
5 hole Stan pot
15” ring

Not level, ring not filled. Trash in piece.

Glass Used in Pot Melt
Result broken for melt 12.

12

11/17/10
Noon
7am

Broken pieces from above two pot melts in blue and green. Plus opaque cobalt blue (6 small pieces)

8+ pounds
5 hole Stan pot
15” ring

Full circle. Distorted ring, stuck to ring. Full of kiln wash remains??

Disaster turned into rather cool piece

Pot Melt - Cast Glass

Detail of Pot Melt

13

12/12/10

Blues, greens, clears

6+ pounds
multi-hole pot
15” ring

Came out well.


Glass Used in Pot Melt

Pot Melt - Cast Glass

Detail of Pot Melt
 

14

01/04/11

Clear, orange, amber, 1 piece green on top

3.5 pounds

3 hole pot

12 in. ring

Okay, but all green in one of the three areas. Fair amt. Of bubbles...refired to smooth out. Slumped into shallow bowl.


Glass Used in Pot Melt

Pot Melt - Cast Glass

Pot Melt Slumped into Bowl shape
 

15 4/22/11

Clear, orange, amber, yellow, red

3.5 pounds

3 hole pot

12 in. ring

 

Good result, but denser color than expected. Probably too much opaque glass.

Glass Used in Pot Melt

Pot Melt - Cast Glass

16 5/26/11 Transparent blue, aqua, grape, clear

3.5+ pounds

4 hole pot

12 in. ring

Good firing; blue dominates purple totally, on 1/3" bubble.

Glass Used in Pot Melt

Pot Melt - Cast Glass

17 5/27/11

Clear, lots of transparent grape 6x6”?, aqua 2x2, cascadia 2x3; chips from previous firings, mostly purple and clear, some dichro

3.5 pounds

5 hole pot

12 in. ring

Okay firing, but trash in piece. Stan bowl chipped off and caused some clay in piece. Other trash not id'ed. Possibly from dichro glass? Although color was primarily grape, it was very weak. Blue overtook piece.

Glass Used in Pot Melt

Pot Melt - Cast Glass

18 06/05/11

Clear, white (5-2x3), plum (4-2x2), violet (4-2x2), grape (4-2x3)

 

3.5 pounds
4 hole pot
12” ring

 

Not level, did not fill ring. Also all purples except maybe plum strike lt. blue at these temps

 


(See results below)

19 06/13/11 Refire #18, after leveling shelf   Looks okay, but sure doesn't show much, if any, of all the purple that was in it.

Eventually slumped into "Cloud" 12" Rippled Edged Plate

20 06/13 Fired broken up drape made of clear, blackberry cream and black 4 pounds
melted through galvanized hardware cloth. Vented first 1.5 hours with top open 5".

DO NOT use galvanized metal without complete ventilation. The zinc oxide fumes produced are incredibly toxic leading to debilitating, possibly fatal, "metal fever."

I used this technique based on the recommendation of another glass artist, complete with the above warnings. But I am trying to find scrap perforated  stainless to work with instead.

NOTE: Bought a large sheet of perforated stainless at the scrap yard, had it cut into smaller piece to fit kiln.

Good casting. Minor spalling, due I assume to inadequate venting. Probably vent 2 hours, kiln open 5", then leave top stopper out to reduce spalling and increase ventilation. (No before photo)

21 7/1/11 Clear, greens, blues, plums 4 lb.

approx. 3lb clear to 1 pound color

Stacked on stainless steel perforated with 1/2" holes, over 12" fiber-lined ring

 

Tremendous glass movement (sliding), appalling spalling of stainless. Black flakes everywhere. Looked awful with chipped glass and rounds of glass and black flakes all over everything. Surprise! None of the broken glass or spalling showed up in the piece--it all just fell away. As for piece itself, too much clear.

This piece made it through a fuse firing and had nice edges.

However bottom photo shows what happens when you slump in a very shallow mold at too high a temp. Other pieces in this firing were okay. Might have survived in deeper mold, but I wonder.

  6/12/12 Pieces recombined in 12" casting ring. Made decent slab for fire polishing    
22 7/1/11 Orange, yellow, clear, green 4 lb  3:1 ratio Stacked on stainless steel perforated with 1/2" holes, over 12" fiber-lined ring Same spalling  mess as above. Piece it self had better color saturation.

Piece cracked and partially healed during fire polish. Must slow down fire polish, fusing or slumping to about 50 degrees for first ramp.

 

 

23 7/16/11 Blues, white, clear 4.5 lb. Maybe half and half clear to color Stacked on stainless steel perforated with 1/2" holes, over 15" fiber-lined ring Did not fill ring. Right side of kiln too high. 2 major cracks on both sides of piece.

 Broken up and used in 25 & 26

24 7/16/11 Brown, almond, amber, white, bronze

3.5 lb 1:1 ratio

Stacked on stainless steel perforated with 1/2" holes, over 12" fiber-lined ring Came out orange circles. Not at all what I wanted.

Decided I liked back side better, so flipped piece over and fused. It cracked and one section split away. Edges soft, so it happened early in firing, probably ramp up.

Couldn't even cut it up for inserts or jewelry base.

  6/12/12 Broke up pieces and refired in 12" casting ring. Nice slab for fire polishing   Shelf STILL not quite level
25 9/2/11 Casting of lots of broken blue scrap from previous pot melts and firings. Plus green strips laid on top. Probably 7-8 pounds in 15" ring. Firing on pot melt schedule came out beautiful.

 Cracked to pieces in fuse firing.

I could have cried.


Finally - Lazy Susan!

6/12/12 Filled 12" ring w/ shards and more clear glass. Got nice thick slab to fire polish.   Shelf not level--heavy on one side
26 9/2/11 blue scrap from failed melts 4 lb. in 3 hole pot Melted okay except surface pitted. Tried fire-polishing, still pitted (old dichro bits?). Put frit over pits and full fused. Shelf not quite level, so not a good circle. Made into shallow bowl, with little to say for it.
Major Hiatus from record keeping - plenty of glassed fired, but records not kept
27 6/18/12 Kiln pressed glass: 10" clear blank w/ transparent and clear colors on it. Covered with shelf and kiln-ware. Full tutorial at http://fusedglass.org/
learn/project_tutorials/kiln_pressed_glass
3.5 pounds total on shelf. 10" spread to 12"

almost 6 lbs after  second layer added

Came out okay, but needs that second layer. Pretty much covered w/ clear glass and added more transparent and clear

Okay on second fire, but need to build little mountains of glass to cause spreading. And MORE weight on top of shelf.

           

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