How to Fuse Copper into Glass

Copper inclusions add an interesting dimension to your fused glass designs. Here we fused a horse shaped piece of copper sheet between a sheet of green and clear glass to create an enchanting cabochon that was used to make a pin. This tutorial will explain how to use copper sheet and wire in your warm glass creations.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Fusible glass
• Copper sheet, foil, screen or wire
• Glass cutter
• Glue, such as Glastac, Klyrfire or Elmers (optional)
• Small kiln (glass kiln, jewelry kiln, enameling kiln)
• Shelf prepared with kiln wash

1. 
    

   A small amount of copper wire, screen, sheet or foil can be added to your fused glass creations. For best results, the copper should be limited to no more than 20 percent of the total size of the piece and the copper should be laminated between the glass.

2. 
    

   Clean your copper with acetone to remove any dirt or residue that could contaminate and react with the glass. Rinse with water.

3. 
    

   Cut out your copper. You can use scissors, a knife or craft punch to cut out your copper designs from copper foil or sheet.

4. 
    

   Copper wire can be cut with a wire cutter or jewelry saw and then formed into your desired shape. Copper screen can be cut with snips or a craft punch. Depending on how you shape wire, air may be trapped when the piece is fired and bubbles may form. If you do not want bubbles surrounding your inclusions, consider how the shape will allow air to be released from your piece as it fuses. For example, complete circles are likely to trap air. Open arcs are more likely to release air. Of course, sometimes the bubbles are part of the attraction and can add to the design, as when copper screen is fused into glass.

5. 
    

   Place the copper onto the glass as part of your design. Take care when placing the copper to be sure you do not leave fingerprints. When you are done arranging your design, cover with a clean clear piece of glass.

6. 
    

   You can use a touch of glue, such as Glastac, Klyrfire or Elmers, to hold the copper in place when moving the design from your work space to the kiln. If you choose to use glue, it is important to wait until the glue is completely dry before putting the laminating piece of glass over the design and putting the project into the kiln.

7. Do not place the copper near the edge of your piece. Copper inclusions that are close to the edge may interfere with the fusing of the glass.

8. 
    

   The copper will oxidize and turn a reddish brown during the fusing process. This is normal. Remember, the cleaner and less oxidized the copper inclusion is before it goes into the kiln, the brighter the color is likely to be after fusing.

9. 
    

   The copper can be embossed to add texture and depth to your piece. To emboss the copper sheet in preparation for fusing, place the copper sheet on a soft surface (a computer mouse pad or a magazine are both good choices) and trace the pattern you desire with a pen.

10. Copper inclusions in glass must be fired very slowly in the first ramp. Heat the glass only 150 degrees Fahrenheit per hour until the glass reaches 350 degrees Fahrenheit. Hold the glass at 350 degrees Fahrenheit for 30 minutes before proceeding in your fusing cycle.

Tips & Warnings

• Projects should not be placed closer than 1 inch form the kiln elements.
• To avoid thermal shock, do not open the kiln when its temperature is between 500 degrees Fahrenheit and 1000 degrees Fahrenheit in either the heating up or cooling down phases of fusing.
• Although it is best to wait until the piece is room temperature, you can remove it from the kiln once it reaches 300 degrees F. Be careful as it will still be hot.
• The best practice is to allow your fused piece to remain at room temperature for 18 to 24 hours before placing it in water and washing it.
• Grease or dirt on the copper will increase the likelihood of bubbles and uneven or ugly oxidation. Be sure your copper is very clean before placing it into the project for fusing.
• Never leave a kiln unattended when firing.
• Always wear eye protection when cutting glass.
• Always wear a dust mask when working with glass particles.
• Glass, particularly vintage glass, may contain lead. Copper may also contain very small amounts of lead. This project is not intended for children ages 12 and younger.

Resources

• GeltDesigns
• Glass and Jewelry Making Tutorials Listed by Topic

[jenniferrealtor]

on 4/22/2009 Very interesting and you are very talented. thanks for the article