These are the steps in the process of making Nielloware
1. Making the Niello Amalgam
Each Nielloware artist has his/her own formula for the composition of the Niello amalgam. After combining the desired amounts of silver, copper and lead in a crucible, melt the mixture in a forge at 300°C for four hours. Continue by mixing the amalgam with sulphur making sure there are no bubbles or scum. Then pour the amalgam on a clean flat container. When the amalgam dries, it should have a black color with a light blue luster. The amalgam is hard and has a low melting point. It is usually kept in the shape of rods or it may broken into small pieces. In some cases this procedure takes approximately 12 hours (Kongwan, Songwut, personal communication, July 15, 2000).
2. Shaping the Object
Form the metal in the desired shape either by hammering (traditional method)
or by stamping or casting.
3. Drawing Patterns
Draw the patterns chosen on the object, either directly (traditional method) or using screens.
4. Engraving or Chiseling Patterns
Carve the design into the metal by hand (traditional method) or by using either acid or stamping machines.
5. Applying the Niello Amalgam
Mix Niello amalgam powder with soldering flux and fill in the carved-out design. Apply heat, typically by using a soldering blowpipe, in order for the amalgam to dissolve and to adhere firmly to the object. The level of the Niello amalgam on the object should match closely the level of the silver. Once the amalgam is applied evenly and thoroughly to the whole object it is set to cool. In this step of the process the artists are extremely careful so there are no minute holes (known as ant eyes) in the niello surface.
6. Filing
File and sand the surface to make it smooth, and to remove any overflow of amalgam on the design.
7. Reshaping the object
Correct any possible alterations in the shape of the object resulting from the heating process.
8. Polishing
Sand the object with very fine sanding paper. Then rub the object with special softwood charcoal until the surface is smooth. Proceed to polish by hand using cotton and metal polish substances, then wash and dry (traditional method) or polish using a machine and benzine.
9. Engraving
Touch-up the images by adding finely chiseled details to the design. This
is a crucial step to make the design more intricate and refined.
10. Burnishing
Polish the finished piece by hand using cloth and metal polish (traditional method) or polish using a machine and finally rub the object with a soft piece of cloth.
In addition, to silver Niello there is also gold-encrusted Nielloware. Gold-encrusted Niello results from adding a coat of gold and quicksilver to the Niello object. In order to transform silver Niello into gold-encrusted (or gold Nielloware). The process of making gold Nielloware requires: preparation of the gold amalgam (wet gold), and preparation of the nielloed object (which has been created according to the steps described above though it has not received the final touch up or burnishing). Then the gold amalgam is applied repeatedly to the object. Once the wet gold is applied, the object is heated to cause the quicksilver to evaporate, paying attention not to apply excessive heat that would melt the amalgam. The last steps are to wash and polish the object, to engrave and touch-up the design and finally to polish the object.
The processes described here are the result of information received in personal interviews with Niello artists Mr. Chum, Mr. Songwut Kongwan, professor Wichian Na Nakon, with descriptions in the Encyclopedia of Southern Culture, in the article written by Hongsyont Sa-ard, and in the book Silverware in Thailand by Punjabhan Naengnoi.