All of our pewterware pieces are made entirely by hand, by several skilled artisans, one piece at a time, using the ancient art of sand casting.
First an artist sculpts a new piece in clay and then casts it in plaster. From that piece, artisans hand make an exact copy from which a single metal mold is made.
This mold will then be placed between two wooden boxes that get filled with a fine sand that holds the precise shape of the mold when it is pounded tight by skilled workers. Once the sand envelops the design, the artisans remove the top box and pull out the mold, leaving the perfect sculpted space in the remaining box.
The artisans then push tubes through the sand to make flow channels for the premium quality alloy of molten aluminum to be poured into this design cavity. Once the molten aluminum reaches the optimal heat, the artisans pour it down the flow channel until the cavity is full. The two boxes will remain tightly joined until the aluminum cools.
At this point, the artisans break open the box. The sand will spill out and be reused, while a team of polishers work on the newly created piece. It will be polished many times by grinding and buffing wheels until it reaches its characteristic high gloss and lustrous finish.