Gary Seymour Designs

Ceramic Sculptor
and Designer


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"Sculpture is a study of infinite profiles"
                                        Auguste Rodin

This section follows the progress of a new design from the initial modelling stage through to moulding and the first finished piece. For ceramic reproduction the master models are generally modelled in clay and plaster of paris blocks. I like using clay for figural pieces and more demanding geometric shapes I use plaster blocks cast from a box or an old margarine box! For the purpose of demonstrating, I have used a new design the Burj Al Arab hotel in Dubia, which ultimately could be used as either a tea pot or a coffee pot. The whole modelling and moulding processes take a lot of intense study and at least 25% of the time taken to complete it is taken up by working out in my mind how to achieve my ultimate goal. I have therefore, tried to make the subtext easy to understand and less technical.

Where ever possible, I like to research the subject matter either by visiting places, books on the design or by photo and the internet has made research a lot easier. I have not had the fortunate of visiting the Burj but managed to obtain many photos of the hotel from a great many angles, so in this instance it is truly an artistic impression but with an eye for correct detail, something that is important for potential customers. Being geometric in shape, I decided to tackle the project in a harder medium than clay. In this case plaster blocks, which I have cast up ready to use for different purposes. Plaster modelling is a gradual building up process. Many areas are carved individually and glued to the model with fresh wet plaster used to blend in gaps and wet and dry sandpaper applied to give a smooth finish where applicable. Initially, I study the overall shape and outline of a design and break it down into basic shapes.

The Burj has a lovely curved sail like shape to it, so this was the starting point on its journey. I have carved a rectangular block always working to centre lines for accuracy. Notice at the side I have drawn the profile line of the curve ready to be carved.

Burj - Gary Seymour

The basic shape and profile has now been achieved. I now have a basic outline to work on and add too.

Burj - Gary Seymour

Marking out the front canopy shape. It's all about measurements!

Burj - Gary Seymour

To get a perfect curve shape to the canopy I cast fresh plaster onto the front of the model using clay walls as a guide. This canopy section will be carved separately and added on at a later date.

Burj - Gary Seymour

This shows the individually carved pieces of the outer structure of the hotel. The component parts are taking shape!

Burj - Gary Seymour

Carving out the front windows. A painstaking process! Notice the side windows are all measured and lined out ready to be carved into. I have used a blue water colour wash just to emphasise the slight depth and outline of the front profile.

Burj - Gary Seymour

This shows the completed ribbed canopy on the front now glued in place. The exterior structures of the Burj have also been added. In reality these structures stand proud of the hotel but this would be virtually impossible and impractical for ceramic reproduction so I've added them to the main building as they are an important feature. Artistic prevails here! The clay pellets are there just to give support to the individual pieces as the glue sets.

Burj - Gary Seymour

The side windows and exterior structure have now been added to the model and the top of the front canopy has been cut out ready for a carved spout to be added.

Burj - Gary Seymour

The lid almost finished and offered to the model to check continuity of profile and just to see how it looks. This was the most challenging lid I've ever modelled. The air was blue at times! The spout has now also been added.

Burj - Gary Seymour

The handle has now been carved and temporarily put in place to see how the piece looks and works overall. It now resembles a teapot!

Burj - Gary Seymour

Finished model.

Burj - Gary Seymour

Starting to mould the piece. The finished moulds are made from the same material as the model - pottery plaster. The age old process of 'slip casting' (liquid clay) is used for the reproduction of the piece so precision is required! The model is sectioned off using clay walls to divide areas which cannot be cast as a whole. I used a made up box of chip board cut to suit to form the exterior of the mould. Here the main section of the mould has just been created by pouring wet plaster into the box. This will take a while to set hard before release so I work on the add on moulds.

Burj - Gary Seymour

The handle gives a good example of a simple two piece mould. Half of the depth of the handle is buried in clay to blank off the area before fresh plaster is poured onto the top half.

Burj - Gary Seymour

The base of the model is now completely encased forming a new mould which consists of six sections - top, bottom and four sides.

Burj - Gary Seymour

This photo shows the finished moulds of the handle and add ons. Notice the round sphere lugs on each section. These help lock the mould together when being assembled for casting. Simply made by notching a two pence piece into the hardening wet plaster!

Burj - Gary Seymour

The first hollow clay cast from the mould. This will be ready for firing within 24 hours. Can't wait to paint one!

Burj - Gary Seymour

The finished piece, painted and glazed. The gold is an on-glaze luster. This is applied to the cold glaze surface and then fired to fix it permanently. Used appropriately it can give a luxurious feel to a design.

Burj - Gary Seymour