Segmented Turned Bowls-The Process
MADERA bowls are constructed of various exotic and domestic woods selected to show off their remarkable colors and grains. After designing the approximate shape, size and pattern of bowl desired, strips of each wood chosen are cut into segments and the segments are glued together into rings. The rings are then sanded and glued into a stack of rings on a base piece to form the rough bowl. The rough bowl is placed on the wood lathe and turned by the use of cutting tools such as gouges and scrapers to the desired shape. After shaping, the bowl is sanded. The MADERA logo is burned onto the bottom of the bowl and five coats of finish are then applied by hand. The bowl is lightly sanded between coats of finish. When the final coat of finish has cured, the bowl is polished and waxed with carnuba wax.
MADERA bowls are functional art--they are meant to be used. The glues and finishes used in the construction process are non-toxic and approved by the FDA for use on utensils and toys. The finish is very hard and resistant to damage by water or any food products. However, it is advised that the bowls be hand washed in warm soapy water and then dried by hand. Occasionally wiping the bowl with mineral oil or a vegatable oil such as canola oil will help maintain a nice lustrous finish.
Metal Series-The Process
The basic process for the Metal Series Bowls is much the same as that outlined above for the Segmented Turned Bowls. Obviously, the difference is the addition of soft workable metals such as copper and aluminum. I believe that I am a pioneer in this process which I began experimenting with in 2001.
Adding the fully segmented metal to my bowls triples the time needed to take a bowl from inception to completion. Different adhesives, epoxies, rather than the wood glues I normally use, are necessary for adhering the metals to the wood; and the gluing process becomes much more involved. The vertical pieces of metal are placed during the gluing of each ring of a bowl. The horizontal pieces of metal are added after each ring has been glued and flattened on their horizontal surfaces. Cutting the metal to shape and routing out where the horizontal pieces of metal will be located add a great amount of time to the building process. When I have progressed to the turning phase, I cannot remove material nearly as aggressively as I would in a bowl with only wood. I use the same high-speed steel turning tools that I use for a total wood bowl, but I need to re-sharpen these tools 2 to 3 times more frequently when metal is involved. At the end, the final sanding process is much more tedious. If I sand too aggressively, the metal will overheat and the epoxy glues will soften up allowing individual segments of wood to "slip" from their glued location--a BIG PROBLEM! In addition, the physical tension that builds in my body is remarkable. After about an hour at the lathe, working on one of these bowls, it's time to go play with the dogs or do some clean-up, anything other than working on that bowl!
To my eye, the final work is very exciting and unique! The highlights of metal around the vivid wood colors in various patterns is stirring at the least and unique for sure. Although I advertise all my pieces as "fully functional", I do view the "Metal Series" more as art to be displayed rather than used. There is a great difference between the two materials--wood and metal--and their response to the environment. Wood and metal expand and contract at very different rates. As a result, one can feel the difference between the two materials on surfaces of the bowl. These differences of movement within the metal bowls disrupt the protective film of the finish. While the "Metal Series" bowls can certainly be used for things like whole fruits, such as apples or bananas, I would advise against using them for "wet" applications such as a fruit salad.
