Manufucturing process

 Manufucturing process of Tetubin by
 LOST WAX CASTING METHOD

  ①  Prototype and copy mold creation
　　 　 First of all, create a prototype with plaster based on the design.
    　　 Next, a replica silicon mold is created from the plaster prototype.


　②  Wax mold creation.
　　　　　Attach a core (to create a cavity) in a silicone mold and pour the molten wax.
　　　　　Once the wax has cooled and solidified, remove it from the mold.
　　　　　Prepare this wax mold for the number of pieces that the kettle master plans to produce.
　　　　

   

　　

　③　Ceramic firing mold creation and dewaxing
　　　　　　Put layers of special sand on the surface of the wax mold which made in step ② then, 
               fire it in a kiln to create a ceramic mold.
　　　　　　The wax melted by the heat discharges out of the mold, leaving only the iron bottle shaped
               cavity in the ceramic mold.

     


　④　Casting
　　　　　　Pour the iron melted at 1800 degrees into the firing ceramic mold made in step ③.
               The craftsmen pour carefully into each mold by hand.
               The cavity inside the mold is narrow and complex, and ironing is sensitive to temperature and 
               humidity. It is only the experience and skill of craftsman to pour iron evenly inside the mold.
　　　　　　Then, slowly cool down.
　　　　　

　⑤　Processing
　　　　　　Break the mold with a hammer and take out the cast iron kettle. 
　　　　　　Carefully off the mold sand baked on the surface of kettle then, polish the excess protrusions such as
               burrs to prepare the surface.

　⑥　Hardening
　　　　　　Place them in the kiln and bake them. When iron is heated, it forms a film on the surface, making it
　　　　　　strong and resistant to rust.
               This process is repeated twice to increase the durability of the iron bottle


　　　　　　
　⑦　Coloring
　　　　　　To get the black deep color, repeat the process of applying iron powder, iron vinegar and Japanese lacquer 
              with brush while heating the surface.