5.1 Techniques and production of Gothic stained glass

Gothic stained glass was a masterpiece of medieval craftsmanship. Artisans used colored glass, intricate painting techniques, and lead cames to create stunning windows. The process involved careful planning, skillful glass cutting, and meticulous assembly.

These windows weren't just pretty – they were storytelling powerhouses. Vibrant colors and detailed designs brought biblical scenes to life for churchgoers. The techniques used to create these windows shaped the look of Gothic architecture for centuries.

Glass Types and Coloring Techniques

Colored Glass Production Methods

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• Pot metal glass created by adding metallic oxides to molten glass during production, resulting in glass that is colored throughout (cobalt blue, copper green)
• Flashed glass made by dipping a gather of colorless glass into a crucible of colored glass, creating a thin layer of color on the surface
  • Flashed glass allows for more subtle color variations and the ability to create multiple colors on a single piece of glass (ruby red)
• Grisaille involves painting black or brown vitreous paint onto the surface of colorless or lightly tinted glass
  • Grisaille adds fine details, shading, and patterns to the glass (foliage, drapery)
  • Grisaille paint contains ground glass and metal oxides that fuse with the glass surface when fired

Decorative Techniques

• Acid etching uses hydrofluoric acid to create translucent patterns or designs on the glass surface
  • Acid etching allows for intricate, lace-like patterns and lettering
  • Areas not meant to be etched are protected with an acid-resistant material (wax, resin)

Design and Assembly

Planning and Preparation

• Cartoon design refers to the full-scale drawing or template used as a guide for the stained glass window
  • Cartoons are typically drawn on sturdy paper or cardboard and indicate the placement of each glass piece and lead came
  • Cartoons may include color notations and other important details for the glaziers
• Lead cames are H-shaped strips of lead used to hold the glass pieces together and define the design
  • Lead cames come in various widths and profiles to accommodate different glass thicknesses and create visual interest (flat cames, round cames)
  • Lead cames are flexible enough to be shaped around curves and intricate designs

Structural Support

• Armature refers to the metal framework, usually made of iron or steel, that supports the weight of the stained glass window and holds it in place
  • Armatures are designed to withstand wind loads and other environmental stresses
  • Horizontal and vertical bars within the armature, called saddle bars and T-bars, respectively, provide additional support and stability
• Glass cutting involves using a glass cutter and grozing pliers to shape each piece of glass according to the cartoon design
  • Glass cutters score the surface of the glass, allowing it to be broken along the desired lines
  • Grozing pliers are used to nibble away small amounts of glass for precise shaping and fitting within the lead cames

Production Process

Firing and Assembly

• Firing process involves placing the painted and stained glass pieces in a kiln to fuse the vitreous paint or silver stain onto the glass surface
  • Firing temperatures typically range between 593-816°C (1100-1500°F), depending on the type of glass and paint used
  • Multiple firings may be necessary for complex designs or layered paint applications
• Once fired, the glass pieces are assembled according to the cartoon design, with lead cames fitted around each piece to create the final composition
  • The joints between the lead cames are soldered together for stability and weatherproofing
  • A waterproof cement or putty is applied between the glass and lead cames to further seal the window and provide additional support
• The completed stained glass panel is then installed into the armature and mounted in the window opening, ready to illuminate the interior space with vibrant, colored light