In completion of my graduate work here at the North Carolina School of the Arts, I decided to research and experiment with different methods of creating breakaway props, a form of special effects often used in theatre, film, and live performance. The term “breakaways” refers to any
object that is planned to break in a specific and realistic manner and is, most importantly, safe for the actor. Affordability is a major issue, especially if there is more than one performance because breakaways are, usually, an expendable. Many artisans assume that creating their own breakaways, especially glass and ceramic items, is unfathomable and that purchasing them from a specialty vendor is the only option. My research over the past year includes mold making, various methods and products for the breakaway casting of glass and ceramic mediums, and breakaway furniture joinery.
This article will explain one form of casting researched within my thesis work: sugar glass. A method of breakaway glass casting that anybody can do. All you will need for the casting material is a mold and some simple ingredients you can find at the grocery store. A mold made out of silicone is preferred because the cast will be fragile and having a mold that is flexible enough to peel away is ideal. Make sure the silicone is able to handle high temperatures because the sugar mixture will be around 300 F° when poured. TO GET STARTED YOU WILL NEED:
The Materials: -The Mold -Granulated sugar -Water
-Cream of Tartar -White Corn Syrup
The Tools: -Measuring cups and tablespoons -Candy thermometer -A stove -An oven -A pot or saucepan -Spatula -Rubber bands
Safety Equipment: -Oven mitts -Apron1. Sugar glass is temperature sensitive, so the molds must be pre-heated so not to put the heated mixture into hard shock once it makes contact. Place them on a cookie sheet in an oven set to 200 F° with the door cracked open for five minutes.
2. In a pot, mix together: 3 1/2 cups of granulated sugar, 1/4 teaspoon of cream of tartar, 2 cups of water, 1 cup of white corn syrup
Once thoroughly mixed, place a candy thermometer inside the pot. Set it on a hot plate or burner, turning the heat up gradually until it comes to a boil. Raising the heat slowly will help prevent the mixture from burning and darkening. Keeping track of the temperature is key in this process.
3. Leave the mixture alone and let boil, unstirred. After ten minutes, it should begin bubbling and rising. The temperature will reach about 200 F°. This is a good point at which to remove the molds from the oven and prepare them for the pour.
Ten minutes later (225 F°) the sugar will still be at a constant boil but will begin to lower in level. Within five min. or so (245 F°), most of the water will boil off and the mixture will sink to its lowest point.
4. At this point, the temperature of the sugar will begin to rise fairly quickly and boil at a sludgy consistency. Once the sugar hits 300 F° it is ready to pour immediately.
5. The sugar will continue to froth and bubble for a few seconds but will settle out and begin to solidify.
6. After 20 minutes the sugar glass pane is ready to be removed. It will still be warm and slightly tacky, but removing it from the mold and placing it on a piece of wax paper will help expedite the cooling process. And V oila! Y ou have your own homemade breakaway glass! The sugar glass does not have a very long shelf life, especially in high humidity areas, so be sure to use it within a few days and keep it refrigerated, ideally, minutes before use.
