Captured in Glass: A Behind-the-Scenes Casting Process

There’s something meditative about turning raw materials into a permanent object. In this post, I’m taking you through the step-by-step process of casting glass using the lost wax method — from sculpting a wax model, to firing the mold in the kiln, all the way to holding your finished glass form.

This guide is perfect if you’re new to kiln-cast glass or just curious about the process behind the glow.

🔶  From Wax to Mold

Step 1: Sculpt the Wax Model

Begin by shaping your artwork in casting wax. You can either carve by hand or pour wax into a silicone mold to create your form.

🧡 Keep details simple for your first piece — fine lines may be lost in casting.

Step 2: Mix & Pour the Mold Material

Combine high temperature with water to make your mold mixture. Stir gently to avoid bubbles. This mixture will capture the shape and texture of your wax model. Slowly pour the plaster-silica mix around your wax model, starting from the lowest point to reduce trapped air. Let it cure for several hours until solid.

Step 3: Remove the Mold Wall

Once the mold has set, gently remove the outer wall. You’ll now see your wax model perfectly encased in the hardened mold.

Step 4: Burn Out the Wax

Use a steamer or fire up the kiln to melt the wax out of the mold — this is the “lost wax” step. What’s left behind is an empty cavity, ready to be filled with molten glass.

🔥 From Mold to Finished Glass

Step 5: Load the Glass

Add crushed glass, frit, or billets into (or above) the mold depending on your setup. Clean glass works best — avoid touching it with bare hands.

Step 6: Place in Kiln

Set the mold on a kiln shelf and position everything carefully. Partially vent the kiln at first to allow gases to escape.

Step 7: Remove the Mold (Divesting)

Once cool, carefully break away the mold. Use water and soft tools. What emerges is your glass piece, still rough but full of promise.

Step 8: Coldworking & Finishing

Use diamond pads, grinders, or hand sanding to smooth edges and polish the surface. Here’s where you refine the shape, finish, and feel of your glass.

🧡 You can leave it matte or polish it to a high shine — follow your artistic intent.

🌟 Final Reflections

Glass casting is a slow art — a rhythm of shaping, waiting, melting, and revealing. Each piece carries the memory of every phase: the softness of the wax, the precision of the mold, the tension of firing, and the joy of the reveal.

If you’ve been curious about trying glass casting, I hope this behind-the-scenes look encourages you to begin. Start small, stay patient, and let the process guide you.