Bespoke Diamond Tooling for Precision Cast Glass Art
Partner: Max Jacquard Glass
Industry: Glass Art and Design
Bespoke Diamond Tooling for Precision Cast Glass Art | DK Holdings
About the Artist
Max Jacquard, founder of Max Jacquard Glass, is a pioneering UK glass artist whose innovative sculptures blend personal stories with culture, science, and craft traditions. Based in Kent, Max creates ambitious works that he exhibits internationally, as well as leading short courses across the UK, Europe, and the USA.
DK Holdings Ltd has been supporting Max for over 20 years with both our standard and bespoke tooling solutions which allow him to meet commercial demands.
The Task
Max approached DK Holdings Ltd for a bespoke diamond tooling solution to remove the cast glass surface from pre-cast glass cones. Made from a combination of fritted colours, the cones feature a distinctive colour glide that create a characteristic ‘aura’ when lit from behind. These cones were to be used to form the ornate border of the Aura mirror, part of the Brian O’Sullivan collection, which can be seen below.
The Current Method
Max’s original method involved grinding the cones on a flatbed grinder, progressing through different stages of abrasive grit to reach the desired finish. Whilst functional, this method proved to be:
- Labour intensive
- Time consuming
- Inconsistent in finish quality
- Limited in precision
With an increase in demand for the cones, Max was seeking a solution to optimise this process.
The Challenge
Our technical engineers were tasked with developing a custom diamond grinding tool, compatible with Max’s existing equipment, that would reduce the overall grinding time while improving the quality of the finish during the crucial ‘first pass’ stage of polishing the cones. The first pass involves removing the mould-made surface to give the cones an accurate flat surface, making it the longest and most important part of refining.
The Process
After receiving the brief, our technical team had a call with Max to present him with a number of potential solutions. There were initial discussions about using a lathe that would rapidly rotate the cones horizontally during grinding. However, it was agreed that it would be more practical for Max to work vertically with a tool that could rotate around the stationary cones. With this in mind, it was decided that a drill with a central water feed chuck would be preferred to create an even finish.
The team then set to work creating a custom steel-body key tool, electroplated in 100/120 diamond grit. Designed to fit Max’s existing equipment, the tool features 3 waterways that allow for consistent water flow around the cone during the grinding process.
Once the bespoke key tool was received, Max developed a method to clamp the cones in place. By bonding wooden bases to the bottom of each cone, the cone can be clamped and held perfectly perpendicular to the drill base. This allows for high accuracy and consistency in the shape and symmetry of the cones.
The Outcome
Max noted three key advantages of replacing the flatbed grinder with this bespoke diamond tool during the First Pass:
- Less labour intensive.
- Significantly more precise shape and accurate finish.
- Up to three times quicker.
Saving both time and labour, Max was able to optimise his grinding process and take on higher quantity orders through investing in the bespoke key tool. The improved shape and finish have helped to perfect these cones, ready for commercial use on the Aura mirror.
If you are looking for a bespoke Diamond Tooling solution to improve your process, our technical team is on hand to help: info@dk-holdings.co.uk
Associated Products
