At SONMO Ceramics, each piece is the result of a meticulous production process that combines research, technology, and the art of handcrafted ceramics. Below, we invite you to explore each step of our process, where precision and imperfection come together to create unique products.
Research and Development
It all begins with a thorough research and development phase. In this stage, significant effort is dedicated to designing, testing, and perfecting every detail of each piece. Jack Wooley, the mastermind behind SONMO Ceramics, works diligently to ensure that every creation is not only aesthetically pleasing but also functional, practical, and reproducible.
From usability to the smallest details of the production process, each component is rigorously examined. The trial and error method is crucial in this phase, allowing us to identify and correct potential issues before the pieces move into mass production. This initial dedication significantly reduces errors and setbacks, ensuring the production process is as efficient and smooth as possible.
Mold Making
Once the design is finalized, the production molds are made. From a “master” piece, usually crafted from synthetic materials using SONMO’s in-house 3D printer, a plaster mold is created, allowing for easier replication of the original piece.
Molding or Slip Casting
With the production molds ready, it's time to create the first batch of pieces. This process involves pouring liquid clay into the molds and waiting for it to harden. It’s a straightforward process when each prior step has been executed correctly, but it requires patience and precision.
Fettling or Polishing
After removing the pieces from the molds, a manual fettling or polishing process is carried out. This step involves cleaning and smoothing out any small imperfections, ensuring the pieces are smooth and ready for firing. Attention to detail in this phase guarantees the quality of each piece.
First Kiln Firing
The cleaned pieces are loaded into the kiln for the first firing. This process hardens the clay and prepares the pieces for glazing. It’s the first step in transforming raw clay into durable ceramics. The resulting piece is often referred to as a “biscuit.”
Ash Painting
To introduce local variability and specificity, the "biscuits" are painted with a solution made from olive and oak ash from the estate. This technique adds a unique patina with distinctive imperfections and character to each piece.
Glazing
Once the ash solution has dried, the pieces are dipped in glaze, which is quickly absorbed due to the porous nature of the clay. The water in the glaze evaporates, leaving behind a layer of powder that will form the characteristic glassy surface when fired again.
Second Kiln Firing
The glazed pieces undergo a second high-temperature firing. This process transforms the glaze into a smooth, glossy surface, revealing the final colors and effects of the glaze.
Sanding
Finally, the bases of the pieces are sanded to ensure they are smooth and stable. This final touch ensures that every piece meets SONMO Ceramics’ high-quality standards.
SONMO Custom Ceramics
Creating custom ceramics at SONMO allows anyone or any brand to turn their vision into a tangible reality with the help of an expert team. We have a team of skilled ceramicists who design and craft each piece with dedicated attention, ensuring that each creation is unique. Now, we offer you the opportunity to be part of this creative process. You can customize pieces from our existing collections or, if you’re feeling inspired, create an entirely original ceramic line. The possibilities are as wide as your imagination. Learn more about the process at this link.
Constant Innovation
At SONMO Ceramics, innovation is ongoing. We continuously experiment with materials and processes to improve our production methods. This approach allows us to maintain a balance between precision and the natural uniqueness of handmade craftsmanship.
The SONMO Ceramics production process combines the sophistication of technology with the natural imperfections of artisanal work, resulting in unique, high-quality ceramic pieces. Each stage of the process reflects our commitment to excellence and authenticity, making every piece a work of art in itself.
The pieces created through this entire process can be viewed on SONMO’s website via this link. And you can learn more about the processes we follow on our YouTube channel.
