Frosting is a decorative technique where glass glaze powder, of a specific particle size, adheres to the surface of glass. When baked at temperatures between 580°C and 600°C, the glaze melts and forms a color that contrasts with the glass body, creating an attractive visual effect.
The process typically involves applying the glaze using a brush or a rubber roller, or through screen printing. A pattern is first printed onto the glass using a flux-blocking agent. After drying, the glass undergoes frosting. During high-temperature baking, the frosted areas without the pattern melt into the glass surface, while the areas covered by the screen print remain unmeltable due to the flux inhibitor. This results in a transparent design appearing through the frosted surface, offering a unique aesthetic appeal.
The frost-resistant screen printing paste is made from materials like iron oxide, talc, and clay, ground to a fineness of 350 mesh and mixed with a binder before being used for printing. This ensures even coverage and consistent results.
The process of making frosted glass includes several steps: designing the pattern on a computer, preparing the screen, printing the etching ink, rinsing the glass, and finally finishing the product.
1. **Design**: The desired pattern is created using a computer. Small designs can be printed with a laser printer, while larger ones are either engraved onto a black sticky note or output via a laser phototypesetter.
2. **Screen Preparation**: A polyester mesh with 100–180 threads per inch is typically used, with monofilament mesh being the preferred choice for better quality.
3. **Printing**: Before printing, the glass must be cleaned thoroughly. The frosting paste should be well mixed and applied carefully. It's best to avoid using iron tools and instead use bamboo or wooden ones. When printing manually, the ink is spread across the screen twice to ensure adequate coverage. In colder conditions, the ink should be warmed to between 20°C and 40°C for optimal performance. It's important to use float glass rather than flat glass, as uneven thickness can lead to an inconsistent etched appearance after baking.
4. **Rinsing**: After printing, the glass is left for three minutes before being rinsed in a water bath or under running tap water. Once dry, it displays a snow-like pattern, which is highly popular among consumers.
This technique is widely used for producing items such as tea sets, handicrafts, gift glasses, and glass containers, offering both beauty and functionality.
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