Nouveau Lantern Project

JN Design recently completed an intensive round of restoration and reproduction of these intricate and historic lanterns.  Two large French style original brass lanterns, provided by the client, were created some time around the turn of the century.  Also provided were two large cast iron sconce armatures believed to be of same period but Spanish origin.  

The job consisted of research, restoration,  design study, prototyping, and production of 5 new mounting variations and reproduction of 26 of these light fixtures in three scales; (2) 36"original size lights, (16) 24" medium size, and (10)16" small.  Mountings included (4) wall variations and (7) canopy style mounts.  All of these were built using molds and sculpted parts following the motif of the originals.  Each lantern had 64-72 parts which were cast, fabricated, machined, and intricately cut using abrasive water jet technology, mills, welders, glass working equipment, etc.    

90% of the components were cast or fabricated in our studio.  The original fixtures were completely dismantled, all parts cleaned, molded where feasible, and then put back together.  In this case, one each of the original mounts and lanterns was more complete than the other.  Missing and broken parts were replaced by bronze ones.

Parts were were welded back into place using a TIG machine and bronze wire.  

Wax parts either sculpted or taken from silicon molds are melted to a wax stem called a sprue. They are then dipped into a green batter of silica called "the slurry" and then rolled in a sand box of dry silica sand to "stucco" over the wax.

  This process is repeated 5-7 times.  Dipped pieces are dried thoroughly between coats to ensure a strong shell.  Sometimes extra sprues are added to ensure that no air will be trapped inside when the molten bronze is poured into the void where the wax has been removed.  

The melted wax is recycled for future mold forms.  Once the wax has been removed, the shells are cooked at 1400 deg. F until all wax and residue is removed.  The cooked shells turn all white then a dull hot red when ready.  The molten metal is poured directly into the hot shells and allowed to cool slowly.  

Pouring liquid bronze is really beautiful and with the heat at 2000 deg. F it is quite intense.

Once cooled, the poured bronze is removed from the silica shells.

The sprues are cut away and the pieces are sanded, wire wheeled, detailed, and polished.  The parts are welded together and more detail finishing is done. 

When the lantern bodies have been assembled, they are ready for glass.  These lanterns required eight curved, trapezoid shaped glass panels per fixture.  Blown glass sheets were used here that are clear and "seeded" with tiny bubbles and a great striated texture.  

These flat sheets were cut to desired shape and heat slumped over customized forms made of refractory (high temp tolerant) concrete. The concrete forms were made in sheet metal master forms "fitted" to the lantern panel areas.  The cut glass is laid upon the forms in a kiln and fired to 1250 deg. F to slump into shape.  The glass must be allowed to "anneal" (cool very slowly) for about eight hours or it can shatter or become brittle.  

Once all the metal work is finished, an oxidizing patina (acid) is applied to age the metal and give it that timeless rustic charm. The glass is then set into the lantern framework, the electrical wiring is tediously done, and voila!, 3-4 weeks and 35 man hours per fixture later, you have a beautiful light fixture!  

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