How It's Made: Flattening Hand-Blown Glass Vases | St. Louisville Glass

How It's Made: Flattening a Bottle-Shaped Vase | St. Louisville Glass

🔥How It's Made: Flattening a Bottle-Shaped Vase

Watch Aaron Buchholz demonstrate the fascinating process of transforming molten glass into a stunning flat-bottomed vase

Ever wondered how a perfectly round glass vase becomes flat — or if that's even possible? In this exclusive behind-the-scenes feature, St. Louisville glass artist Aaron Buchholz reveals the intricate and mesmerizing process of flattening a hand-blown bottle-shaped vase.

Whether you're a longtime fan of artisan glass or just curious about the craft, this step-by-step breakdown will give you a deeper appreciation for the skill, heat, and precision involved in transforming molten glass into stunning functional art.

🎬 See the Magic in Action

Want to witness the transformation before we explain it? Watch our exclusive video where Aaron demonstrates the entire process from start to finish!

🔨 Essential Tools & Materials

Before diving into the technique, here are the specialized tools Aaron uses during this intricate process:

Glory Hole
High-temperature reheating furnace for maintaining workable heat
Marvering Surface
For precise shaping and controlled cooling
Punty Rod
Essential for holding the piece while working the opening
Jacks & Shears
For fine-tuning shape and creating clean edges
Graphite Blocks
Heat-resistant tools for smooth shaping
Water-Cooled Paddle
The secret weapon for achieving that perfect flat bottom
🔥 The Flattening Process: Step by Step
1
Prepare the Vase

After blowing and shaping the initial bottle form, Aaron carefully inspects the wall thickness and symmetry. The base must be strong enough to withstand the flattening process without developing stress cracks.

2
Strategic Reheating

The bottom of the vase is precisely positioned in the glory hole to reheat the area until it reaches optimal malleability — hot enough to reshape but not so hot that it loses structural integrity.

3
The Critical Flattening

With the base glowing red-hot, Aaron expertly applies a water-cooled steel paddle against the bottom. This transforms the curved surface into a smooth, stable foundation.

Master's Touch Required: Precision is everything here — too much pressure or uneven heat distribution can cause warping or catastrophic cracking.
4
Surface Perfection

After the initial press, Aaron rotates the piece methodically, applying gentle touches with the paddle to ensure a completely flat and balanced base.

5
Final Refinements

Using jacks and graphite blocks, he meticulously refines the rim and outer edges, ensuring the piece achieves a clean, professional finish.

6
Critical Annealing

The completed vase enters the annealer (controlled cooling kiln) for an overnight process. This prevents internal stress and dramatically strengthens the finished product.

💡 The Art Behind the Technique

Why Not Blow It Flat From the Start?

While some shapes can be blown directly into flat-bottomed forms, certain designs require a rounded beginning for structural integrity. The flattening technique allows for greater creative freedom in design while achieving a sturdy, display-ready finish.

This signature technique ensures each handcrafted piece is truly unique — a hallmark of Aaron's distinctive artistry.

Fascinating Glass Fact

Those stunning flat-bottomed vases in our collection actually began their lives as perfectly round bottles! The entire transformation happens in just a few minutes — but only after years of experience mastering the delicate balance of heat, timing, and pressure.

🛒 Own a Piece of This Artistry

Discover our latest collection of hand-blown and hand-flattened vases, available now in our online shop. Each piece is a true work of art — never mass-produced, always one-of-a-kind.

Shop Our Collection