At Hera Ray, our hardware is more than just a functional addition to your home; it's a piece of handcrafted art, designed with passion and built to last a lifetime from the enduring beauty of recycled brass. We believe in transparency and are excited to take you behind the scenes to explore the journey of how a Hera Ray door knocker comes to life, a process steeped in tradition and driven by your inspiration.
Our Green Foundation: The Beauty of Recycled Brass
At the heart of every Hera Ray creation lies our commitment to sustainability. All our hardware is crafted from recycled brass – meaning no new mining takes place, and existing precious resources are given new life. This not only aligns with our green policy but also imbues each piece with a sense of history and responsibility. Even our black and nickel finishes begin with this solid recycled brass, ensuring enduring quality beneath the surface. Its hard to believe this bar of recycled brass will soon become a gorgeous new door knocker!
Stage 1: Inspired by You
Our creative process often begins not in a dusty archive, but in the vibrant conversations we have with you, our incredible community. We are constantly inspired by the requests and feedback from our wonderful followers on Instagram and TikTok. By sharing new product ideas and inviting your opinions, we gain invaluable insights into the designs that truly resonate. This collaborative approach ensures that our creations reflect the desires of those who will ultimately adorn their homes with them.
Historically, my personal inspiration often stems from the intricate beauty of Victorian jewelry. Just as a charm bracelet or necklace adds a touch of elegance to an ensemble, our door knockers are envisioned as "jewelry for the front door" – adding a unique and stylish statement to your entryway.
Stage 2: From Vision to Paper
In a world of digital design, I still find immense value in the tangible act of putting pen to paper. Surrounded by a curated collection of images gathered from Pinterest and Google, I spend days sketching and refining 4-5 distinct design options. This old-fashioned approach allows for a deep connection with the emerging form, capturing the nuances and details that will eventually translate into a three-dimensional piece.
Stage 3: The Digital Transformation
Once a design direction is chosen, the transition from a 2D drawing to a precise 3D model begins. This crucial stage requires translating the artistic vision into a digital format that can be used for printing and, ultimately, casting. It's where the initial artistic concept starts to take on its physical form within the digital realm.
Stage 4: Bringing the Design to Life (in Resin)
The 3D print is a pivotal step in our process. By creating a physical prototype in resin at the exact intended size, we can truly experience the piece in three dimensions. This allows us to assess not only its aesthetic appeal but also crucial practical considerations. We evaluate the size and weight to ensure it feels substantial yet is suitable for postage. Furthermore, and perhaps most importantly, we meticulously examine the design for any undercuts or intricate features that might pose challenges during the brass casting process. This stage of real-life evaluation allows for necessary adjustments before committing to brass casting.
Stage 5: The Ancient Art of Casting in Brass
The moment of truth arrives with the casting in brass. We utilize two very traditional techniques, honed over thousands of years, to bring our designs to life:
- Sandcasting: This method is employed for many of our designs, creating robust and characterful pieces.
- Lost Wax Casting: For designs demanding an even higher level of intricate detail, such as our Amphibia Frog Knocker and Mermaid Knocker, we turn to the lost wax casting technique. This is the same method used in jewellery making and bronze sculpture, allowing us to capture incredibly fine details and textures.
We typically undertake 3-4 test casts for each new design, regardless of the method, to thoroughly assess the quality of the casting and identify any potential problem areas in the mold or the design itself.
Stage 6: The Art of Hand-Finishing
Once the brass pieces are cast, the true artistry of our craft comes to the forefront. Each piece undergoes a significant transformation through meticulous hand-finishing. This labour-intensive process involves skilled artisans carefully filing and smoothing the brass surface, patiently removing any imperfections that may have occurred during casting. It's during this stage that the inherent beauty of the brass begins to emerge and take form. Following this crucial step, items requiring a black or nickel finish are expertly coated to achieve their desired colour and durability, all while retaining the solid brass core. Finally, for those pieces intended to showcase the natural allure of brass, our skilled polishers bring them to a brilliant, high-shine mirror finish using traditional polishing wheels, a testament to the enduring beauty of the metal.
This journey, from the initial spark of inspiration – often ignited by your very requests – to the final, meticulously finished brass piece can often take many months to get to the final piece we are ready to make available to to our lovely customers. At Hera Ray, every door knocker carries with it the story of thoughtful design, traditional craftsmanship, and the enduring beauty of recycled brass.
Explore our door knocker collection today and discover a piece of handmade history for your home.