Bill Ellis

Break-Away Glass: Formula and Process


While he was Production Manager at the Guthrie Theatre, Terry Sateren developed a simple and easily repeated process for making panes of break-away glass. The process uses a pane of plate glass to make a negative mold for a break-away casting of hydrocarbon thermoplastic resins. It requires very simple tools and produces consistent results.


RefrigeratorStove or ovenElectric saucepotHeat-conducting support plate (we used a ¼″ aluminum plate larger than the final mold)Cooling plate (we used a +½″- or ¾ ″-thick section of glass plate, larger than the final mold)Level cooling stilts (wood or metal)Flexible moldPico® plastic(s)


For a glass pane, the best results (both ...

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