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Our Process

1. Introduction
2. Designing Resin Parts
3. Producing Resin Part Prototypes
4. Producing Pedestals for Putting in Resin
5. Creating Silicone Molds
6. Pouring Resin Into the Mold
7. Completion of Resin Parts
8.Production of Metal Parts
9. From Metal Polishing to Plating
10. Assembly Work
11. Finishing Touch

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1. Introduction


In making accessories, rarely do we draw our designs on paper beforehand. The reason for this is because we come up with the shapes and designs as we make the accessories. The few times we do draw out the designs prior to making it, is when we design metal parts of photographs or resin parts of main bodies. We ask a specialized metal processing company and stone-polishing craftsmen for their help, and they require designs and specifications. Production mainly divides into metal parts and resin parts.

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2. Designing Resin Parts


Producing the resin parts is the most important process for Tamarusan. When resin is made, the first thing we do is name it. This becomes the series name. Hand-drawn pictures are the most common at Tamarusan. We print these designs on either paper or film, according to the texture of the design. In terms of the final product, the main difference is that it will turn out opaque when printed on paper, and translucent when printed on film. When printed on film, the film will reflect a glow the color of the metal fitting on the bottom, or conversely, the color may toned down, so it is important to proceed while observing the resin's compatibility with the metal fittings. Here, a printed piece of paper is used as a template and scissors are used to cut the paper to the size of the finished resin.

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3. Producing Resin Part Prototypes


First, I will draw a design of the shapes of the resin parts I want to make. Next, I will have a stone polishing craftsman process it. Agate and onyx are used for prototypes. Relatively hard stones are selected for prototypes, so it can withstand the many times silicon molds are made from it. When there are many cuts in the stone, light reflects and shines brilliantly. In addition, the refraction of light will change the appearance of the inside pattern. On the contrary, dome shaped surfaces will provide a lens effect to enlarge the pattern on the bottom, so even if two pieces have the same design, if the shape is different, it will mysteriously have a completely different appearance.

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4. Producing Pedestals for Putting in Resin


Producing Pedestals for Putting in Resin Molds are made with metal materials so they fit perfectly with each resin part. Materials used are copper, brass and silver. The entire reverse side is patterned with a design using a portion of Tamarusan's logo. Unevenness is attained by etching the pattern, allowing the pattern to clearly rise to the surface, especially when antique plating is applied.

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5. Creating Silicone Molds


Silicone is used to make the molds. The stone prototype is pasted firmly at the bottom of the container, so it will not move even when silicone is poured in. The silicone is poured in quickly and little by little, in order avoid air bubbles from forming. It depends on the temperature, but it is usually left put for 1 day. Silicone molds become stretched after repeated uses, so they are discarded after 3-4 uses so beautiful resin parts can continue to be made. For larger items, such as resin for loop ties, there are cases when the molds can only be used once.

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6. Pouring Resin Into the Mold


The base and the curing agent are mixed together well. Once it is warmed up with hot water, mixing becomes better and curing defects can be prevented. In order to further remove air bubbles, the silicone mold is placed on a hot carpet and warmed in advance. During the winter, work is done with the heating temperature set very high. Furthermore, applying hot air with a dryer makes it easier to remove the air bubbles. Because the temperature is higher in summer, it is easier to operate and there are less mistakes compared to winter. The resin is finally poured into the silicone mold. Because the mold is very small, there are times when the resin overflows or there is not enough. To solve this, a wire is used to even out the amount as a whole. Next, all the materials of the series, such as paper, film, beads, etc. is placed inside. Depending on the seasonal temperature, hardening time is 1 to 3 days.

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7. Completion of Resin Parts


After a few days, the hardened resin is removed from the silicone mold. This is the completion of a colorful, original, resin part. I match these parts with different colored metals to see how I can bring out the most brilliant shine as I look towards my next creation.

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8. Production of Metal Parts


During the production of the resin parts, there was no need for any direct fire, but in creating metal parts, a gas burner becomes necessary. No designs are pre-drawn here as well, and the production is done without rehearsal. First, in the case of a hairpin, start from where you cut the brass wire, and process the metal with the flame.

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9. From Metal Polishing to Plating


Metals that are shaped with fire will oxidize, so we will get rid of the dirty portions by soaking in sulfuric acid. From there, it is polished carefully with a metal brush. After this, it is sent to the plating factory. If it is polished cleanly, the resulting plating will also come clean.

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10. Assembly Work


When the metal parts come back from the plating factory, we begin the assembly process with the resin parts. The 5 main plating colors are "antique gold", "antique silver", and "antique bronze", 24 karat gold plating, and rhodium plating. In addition, nickel free plating which is less susceptible to metal allergy is used (excluding some). Depending on the resin series, the most suitable colors are selected. Blue types match well with antique silver and rhodium. Green and yellow types with antique gold or gold. Pink, red, and oranges match well with antique bronze and gold.

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11. Finishing Touch


After the resin parts and metal parts are attached with an adhesive, matching natural stones or beads are selected. It is very interesting that they are made, the perfect stone or pearl for each series is naturally decided. This is how the world of one series will expand. As I explained in the introduction, because we do not draw our designs on paper, one of the major pleasures is the unexpected results we achieve in the end.