The sequence displayed at right details the process of forming a 16 inch Rim Sink. This basic blank is frequently altered by inverting the bowl on foam forms to facilitate resizing the blank as required.

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Process

Press Forming

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Press Forming Sinks

Ram Pressing –
is a method for forming clay under extreme pressure to create stable high density forms. Presses are normally used to duplicate molded forms without any skilled alteration.

At Water Stone - we use this tool quite differently. Our master sink is hand thrown (using traditional methods) to create the original model for our working dies. We have only one 18 inch diameter die set which we use to form sink blanks which we resize and reform using traditional throwing skills. We make both Rimmed Style Sinks and Vessels Style Sinks sized from 12 inch OD to 18 OD from this single press formed blank. I developed this hybrid process to combine the advantages of high density press forming and the versatility of hand alteration and finish detailing.

Wheel altering pressed forms requires considerable skill. Although it is easier to throw sinks using traditional methods - our peculiar method produces a superior product by combining the best of traditional and industrial processes.

	Die Setup - Sink dies are carefully aligned on our 60 ton press with stop bars positioned to precisely gauge the sink cross section. The porous die structure is carefully wetted and purged to facilitate the hydraulic air release which is used to remove the pressed sink blank.

	Closing Dies - After setting up the press the dies are closed on a pre-sized plug of clay that has been run through our pug mill. The mill removes lumps and air to guarantee a uniform cross section. As the dies close the clay flows to fill the void and form the bowl blank.

	Upper Die Removed - Retracting the upper die reveals the compressed reverse form of the bowl. Scrap flashed beyond the rim will be stripped and reprocessed with the pug mill for the next pressing. The rough form of the overflow reservoir is revealed at the bowl top.

	Removing Bowl - Re-closing the press from the above photo adheres the form to the upper die where compressed air is used to release the form to a catch board. This bowl blank is examined for forming flaws and then moved under a fan to facilitate stiffening and drying.

Adding Overflow - When the bowl is stiff enough to work the overflow reservoir is completed and the overflow tunnel is added to the side. The sink can then be reversed on its stiffened foot to complete additions and modifications to the rim, inside bowl surface and drain area.

115 South Gouldsboro Road - Gouldsboro, Maine 04607 - danw@waterstonesink.com - 207 963 5819

WATERSTONE – Specialty Sinks & Basins