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Glass Fusing

The art of glass fusing has been around for many years. It regained popularity during the 1960's and has maintained a strong place in artist communities since. Fusing glass in a kiln is a fascinating technique that enables artists to create unique and gorgeous projects, but getting started can be intimidating for artists new to hot glass techniques. The information and tips provided below will provide some basic information and make it easy to get started!

 

Glass compatibility (COE)

The Coefficient of Expansion (COE) refers to the rate at which glass expands and contracts when heated and cooled. All glass has a COE but we don't always know what it is. It's important that all of the glass you are fusing together expands and contracts at the same rate or stress and cracking can occur. Glass manufactured specifically for fusing is tested for compatibility. Always fuse glass with the same COE or tested compatible glass.

Properties of Hot Glass

When heating glass to a full fuse (1450° F) it wants to become ¼" thick and round. A standard sheet of glass is approximately 1/8" thick.

  • When firing a single layer of glass the edges will contract to become ¼" thick.
  • If fusing three layers of glass your glass will expand to become ¼" thick.
  • Unless you are damming the glass, two layers are ideal to maintain your projects original size and general shape.

In the picture below, notice how the following stacks of glass appear before and after firing.

Properties of Hot Glass before firing

In the next picture, notice how each cabochon is approximately the same thickness

Properties of Hot Glass after firing side view

Viewing the cabochons from the top you can see how the stacks spread when they were fired.

Properties of Hot Glass after firing top view

Keeping the ¼" rule in mind with help you achieve the desired effect without growing or shrinking your project.

 

Heating and Cooling Glass

Glass cannot be heated or cooled too slowly. Heating and cooling too fast can result in cracked glass or thermal shock. Ideally you want your glass to stay approximately the same temperature as the kiln. Because the glass heats more slowly than the kiln, you should consider your project size and how long it will take the piece to "catch up" to the kiln temperature.

  • The larger your project the slower you should go 200°– 300° F an hour is a safe speed.
  • Smaller projects, like jewelry, can be heated more quickly – 500° F per hour is a safe speed.
  • Be sure to keep track of the schedules you try so you'll know what works best.

Slow, controlled cooling, commonly referred to as annealing, is the process in which you allow the glass to gradually cool down in order to remove internal stresses that may have occurred during the firing process.

Annealing allows the glass to stabilize and adds strength to your finished project.

  • Ideal annealing temperatures are 900° F for 90 COE and 950° F for 96 COE glass.
  • 30 minutes is usually sufficient for small projects but you may choose longer annealing times for larger pieces.
  • When in doubt, anneal longer; you cannot over anneal.
  • Allow your kiln to cool completely before opening the lid – a rush of cool air into a hot kiln will cause thermal shock and often crack your project. Breaks from thermal shock generally go straight across the piece and have a little hook near the edge.

Never Refuse to Re-Fuse

If your glass breaks in the kiln, your project didn't turn out quite as expected, or you feel the need to add further embellishments to your project, you can re-fire your project until you get the results you desire. For cracked glass some artists add additional pieces of glass to the top of the glass to reinforce and cover the "seam" where the crack occurred. Do not try to re-fire projects with incompatible COEs. Even if the project survives the heating and cooling process the stress remains and the piece can crack or break later.

 

Key Temperatures in the Firing Process

The firing process you select will determine the final appearance of your fired project. Many projects will require multiple firings using different processes before they are complete

 
Temperatures Ranges Fusing Stage Glass Stages
800º F - 1100º F Brittle Zone Do not open the kiln in this range
1250° F – 1300° F Slump The glass is placed on a mold and bent into the desired shape.
1300º F - 1350º F Tack Fuse Edges are soft, glass is stuck together, embellishments are well defined.
1350° F – 1400° F Medium Fuse /Fire Polish Edges are softer, surface is shiny and embellishments are slightly less prominent.
1425º F - 1500º F Full Fuse Glasses combine, thickness is uniform throughout

 

The photographs below show glass projects with similar embellishments, fused at various temperatures.

fused at 1250° F – 1300° F fused at 1300° F – 1350° F fused at 1350° F - 1400° F fused at 1400° F – 1450° F fused at 1450° F - 1500° F
1250° F – 1300° F 1300° F – 1350° F 1350° F - 1400° F 1400° F – 1450° F 1450° F - 1500° F


Common Firing Schedules

The schedule that works for you will depend largely on the size, scope and desired look of your finished piece. The firing schedules below will provide a great place to start.


Full Fuse Rate (Ramp) Temperature Hold (Soak)
Segment 1 300° F /hour 1000° F 5 minutes
Segment 2 300° F /hour 1250° F 30 minutes
Segment 3 300° F /hour 1450° F 10 minutes
Segment 4 Full (9999) 900° F (90 COE) 950° (96 COE)
Slump Rate (Ramp) Temperature Hold (Soak)
Segment 1 300° F /hour 1000° F 10 minutes
Segment 2 300° F /hour 1290° F 10 minutes
Segment 3 Full (9999) 900° F (90 COE) 950° (96 COE) 20 minutes
Tack Fuse Rate (Ramp) Temperature Hold (Soak)
Segment 1 300° F /hour 1000° F 10 minutes
Segment 2 300° F /hour 1340° F 5 minutes
Segment 3 Full (9999) 900° F (90 COE) 950° (96 COE) 20 minutes
Fire Polish Rate (Ramp) Temperature Hold (Soak)
Segment 1 300° F /hour 1000° F 10 minutes
Segment 2 300° F /hour 1350° F 5 minutes
Segment 3 Full (9999) 900° F (90 COE) 950° (96 COE) 20 minutes


All Kilns are Not Alike

  • Your kiln size, controller type, and individual project may require some alteration to the schedules above for best results. Firing times and temperatures may vary, each kiln is unique.
  • Use firing schedules as a guide, but remember to check your piece frequently during fusing, and record changes in schedules as needed.
  • Prepare your kiln by applying kiln wash with a kiln brush. Apply one thin coat in each direction. Don't forget to apply kiln wash to molds, too.

 

Project Firing Logs

Using a project and firing log to keep track of information about your projects and firing schedules can be an extremely useful tool for every artist. Once you've achieved a good result you can reference the logs to re-create the project or simply re-use a firing schedule for a similar project. Click on the buttons at the top of the page for a copy of this document and a project firing log to get you started.

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Jennifer Bonesteel

Tuesday, July 29, 2014
Delphi Expert
188 Posts
Top Contributor Gallery Artist

@cucabee your firing schedule appears to be a good one and I can't see any reason for it not to work for you. Perhaps your temperature gauge is wrong - all kilns vary a bit and this isn't entirely unusual. A solution for that can be simply experimenting with your target temperature (go a bit hotter) and hold times (hold a bit longer.) Another possible issue is that you are loosing heat out the bead door. A solution for that is to simply purchase a fiber blanket, cut it to fit the door, and use it to seal any gaps. If you are using dichroic or iridized glass the edges sometimes don't melt as smoothly as regular glass due to the coating - that could also be a part of the problem. If you continue to have issues please feel free to give our customer service department a call. We are here to help you be successful and enjoy your glass art!

Jennifer Bonesteel

Tuesday, July 29, 2014
Delphi Expert
188 Posts
Top Contributor Gallery Artist

@blaqsmoke you could certainly buy two and put them together to get the length but you will likely have a seam. If you try it I would definitely recommend some fiber paper at the seam.

cucabee

Thursday, July 24, 2014
2 Posts

Hello, I have done stained glass for maybe 10 years, just small things mostly for the enjoyment of making things for myself or as gifts. I recently purchased a used a Jen-Ken Kiln Bead Annealer with a 4 " flip door and with a AF3P ore-programmed "One Smart Controller". After several attempts I have ALMOST got the fused barrettes right, EXCEPT for they all have many "points" of sharp glass around the edges after fusing. I have tried gently grinding them off then doing a fire polish. It did work, but would like to know a way to NOT have the "points" on them to begin with. I asked on a Yahoo fusing group I belong to, and the below #'s were suggested to me. 500 to 1100; hold 30 500 to 1460; hold 20 <<<<< this segment would adjust up or down in time/temp depending upon results AFAP to 950; hold 30 I tired it, the glass looked like it barely got fused at all. SO could someone there suggest something different. I don't want to give up ;-)

blaqsmoke

Friday, July 18, 2014
1 Post

there are some texture molds that are 9x9.....if i have a project 12 inches in length that needed texturing how could i accomplish this......do i need to buy (2) 9x9 to get the 12 inches......do i need to put a piece of thin fiber paper at the connection????

Jennifer Bonesteel

Wednesday, January 29, 2014
Delphi Expert
188 Posts
Top Contributor Gallery Artist

@greenthumbjen there is no limit to how many times you can fire a project. However, the more times a project is fired, the greater the risk of devitrification, especially with opal glass which tends to devitrify more quickly than transparent glass.

greenthumbjen

Friday, January 24, 2014
3 Posts

@comments2 thanks Jennifer. I used 2-3shelfs all the time but will try a little slower ramp up and see. I will try fusing them back together. How many times can glass be melted?

Jennifer Bonesteel

Thursday, January 23, 2014
Delphi Expert
188 Posts
Top Contributor Gallery Artist

@greenthumbjen It sounds like you're firing in a ceramics kiln, which is fine. Glass requires a lot of heat circulations to ensure even heating so shelves stacked directly on top of each other are not recommended. Try slowing to 300 degrees per hour and add a 15 minute hold at about 1000 degrees to let the glass reach the kiln temperature before proceeding.

greenthumbjen

Wednesday, January 22, 2014
3 Posts

@Laceyboo I would not use granite. Have you ever put any rocks in a fire? they explode or at least crack most of the time and granite is afterall a rock

greenthumbjen

Wednesday, January 22, 2014
3 Posts

Please Help!!! I have been slumping bottles in my kiln for the past 2 years and last year started to fuse glass. I have been very successful being it is a large pottery kiln. I slumped a fused coe 90 piece a couple of weeks ago along with some specialty bottles a friend needed. everything great. I fused some very large pieces of glass art and they all came out great. I went to slump 3 large pieces of already fused glass artwork, one on 1"fiberboar with a whole cut out , one on a stainless vase cylinder and one on a Ceramic ring that I had used before. I ramped up the kiln at 500 degrees per hour and once it reached 1300 degrees I cooled to 980 and closed back up and soaked and then cooled. when I opened the kiln to cool the first time I thought the top piece already looked broken. all three levels were broken. Too hot on ramp up when glass is already fused? Bummed Jewelry has come out great and because I have all the pottery supplies I can make countless shapes to slump on and into. I really thought I ramped up at 500 degrees the last time but may have done it at 400 degrees I really did not think that would make a difference.

Jennifer Bonesteel

Monday, January 13, 2014
Delphi Expert
188 Posts
Top Contributor Gallery Artist

@cscheydt as long as you are using a decal that matures at a tack fuse temperature you can absolutely do both at the same time. Gold and other high-fire decals should be done in a separate process as they require hotter temperatures.

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