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Tony Hansen
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Chemistry plus physics. Maintain your recipes, test results, firing schedules, pictures, materials, projects, etc. Access your data from any connected device. Import desktop Insight data (and of other products). Group accounts for industry and education. Private accounts for potters. Get started.

Conquer the Glaze Dragon With Digitalfire Reference info and software

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Interactive glaze chemistry for the desktop. Free (no longer in development but still maintained, M1 Mac version now available). Download here or in the Files panel within your Insight-live.com account.


What people have said about Digitalfire

  • I must say I am amazed by what I saw here. I am even more surprised to see so much of cermaic material stuff here.
  • Tony Hanson is like the person that is always waiting to answer my questions. He is very thoughtful and quick with response. I wish he was my neighbor.
  • What a lovely surprise to find you online. As I've changed to Broadband you were allowed through and I'm really pleased. I'm quite sure your site will be a source of much inspiration.
  • My pleasure -- your database is a wonderful set of reference info, and if I can help make it even more accurate and/or complete, I'm happy to do so.
  • I am so glad I found your site, I have been looking for a site with this type of good information.
  • Your sight ROCKS.
  • LOVE your site! You have saved me a whole lot of work and research time with your materials data base and comments. I haven't gotten to explore your software yet because I'm in the middle of resolving another mess involving raw materials from a certain large company with sloppy production. We are a small company that is developing a low expansion, thermal shock resistant porcelain for industrial use ... Between our acquired data and some clues contained in your comments we were able to pin point the problem.
  • Almost anything I have to say I learned from you. Keep up the great work.
  • Thanks, your website is a wealth of information for me and my students.
  • I am so fascinated by your site I have trouble to leave it!

What people have said about Insight-Live

  • I join others (I'm sure) in thanking Tony for the incredible resource that is the digital fire library, and for the insight glaze calculation software and now website. Not a week goes by when I don't use all three of them and usually quite extensively.
  • THIS IS FRIGGIN' AMAZING! YAY! NOW I NEED GLAZE MATERIALS! WOOT! I'm blown away by your site. I'm totally going to geek out on this I can tell. Item #1 on my agenda is to stop being at everyone else's mercy for glazes.
  • You have done more for the advancement of ceramic knowledge than anyone I can think of. Thanks again! The information you provide and the work you have done is invaluable. I can't tell you how many problems I have solved because of insight and the reference library! Thanks again for all of the help you have provided.
  • I would like to honour my commitment to the great work you do. It is an invaluable resource! Just a huge thank you!
  • Tony, I owe you a tremendous debt of gratitude. In art school, I got a thorough grounding in ceramics -- in a macro sense. Micro, not so much. You, then, are the professor who is helping me to complete my education, via Digitalfire -- truly a Phenominal piece of work.
  • What you have created is a god send to thousands of potters and me.
  • Please know that your work is really benefiting me in my work. I really was helped by your information about drop and soak at cone 6. I've had trouble with an otherwise beautiful glaze which develops blisters. Thanks for your 'Insight!'
  • Your understanding and explanations of glazing process and chemistry are always fascinating. Like the help you give for us amateurs, but also I love the posts explaining how commercial facilities deal with cost and efficiency issues like getting production products rapidly glazed and fired without defects.
  • Most people would lose the ability to troubleshoot how to problem-solve issues with Plainsman Clays without your documentation.
  • Just read your page and I am awestruck!

Monthly Tech-Tip from Tony Hansen

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Blog

Brushing engobe fitted to this white porcelain turns it black

Black porcelain engobe

This L3954F engobe is tuned to have the same degree of vitrification as this P300 porcelain (using EBCT test). I made a pint of a brushing version by mixing a 500-gram batch with 75g of Laguna Gum Solution and 280g water (it does not contain CMC gum but not VeeGum because I want a lower specific gravity than would be typical for a brushing glaze). Blender mixing gets all the lumps out and makes it paint beautifully onto leather-hard ware. One coat covers. This enables presenting this normally white-burning body as a black porcelain to match the glaze.

I was so excited about this engobe that I made my own label. It shows the code number I assigned in Insight Live. Subsequently, the piece was bisque-fired, black-glazed, and fired at cone 6. The band painted on the base, which I did as a fix-up for a few tiny white bare spots, demonstrates something unexpected: It can dry on a vitrified surface without cracking, and this thin layer can even fire on without peeling.

Context: Here s how I.., The best way to.., Is porcelain engobe good.., Engobe

Thursday 9th July 2026

Copper is not just a pigment

It can be a powerful flux

Left: The base recipe of GA6-C (80% Alberta Slip, 20% Frit 3134, 4% rutile). That recipe is stable; it does not run. Right: A 2% addition of copper carbonate transforms it into a runny, melt fluid glaze. It also produces a pleasant green even on this red-burning body (a good green is not easy in oxidation ceramics). Using a catch glaze (e.g. a frit-reduced version), this could be made safe on vertical surfaces. However, there are red flags here. Having only 2% copper would not destabilize a typical glaze (making it leachable). But phase separation is occurring here, likely because the base contains significant rutile. That means the phases are copper-bearing and possibly copper-concentrating. And, as noted, the copper has a greater-than-expected impact on the melt. Third, commercial variegated copper glazes can even leach in acids (as happened with the mug inset after a night with lemon juice). While the GA6-C recipe does have a 0.3:0.7 R2O:RO ratio, other indicators make it a course of wisdom to consider the GLLE test before use on functional surfaces.

Context: Copper Oxide Black, CuO, Copper can destabilize a.., Commercial supposedly safe glazes.., Flux

Thursday 9th July 2026

Mason Color

A company open with information

Mason is unusually information-open for the ceramic stain market. Their public reference guide gives compositions by listing oxides such as Co, Cr, Fe, Mn, Ni, Sb, Ti, Zn, Zr, etc., and then marks which oxides are involved in many stain families. It also gives practical compatibility notes, especially about zinc, calcium, firing limits and body-stain use. Their product pages often identify the crystal system/pigment class. For example, Mason 6630 Black is described as a chrome-iron-nickel black spinel formed by high-temperature calcination of chromium, iron and nickel oxides into a spinel matrix. Mason 6274 is described as a nickel silicate green olivine pigment formed from nickel oxide and silica. It is certainly helpful to know if your stain is, for example, a cobalt aluminate spinel, chrome-tin pink, zircon-vanadium blue, nickel silicate/olivine green, rutile yellow, etc. Mason’s technical table also lists CICP/color-index numbers, CAS numbers, chemical names, specific gravity, oil absorption, mesh residue and pH for some pigment lines. Of course, they don't publish oxide percentages, mineralizers, firing schedule, milling procedure, soluble salts, frit additions, trace impurities or batch tolerances. This being said, they are not completely alone; some others also publish such information.

Shown here are mugs I glaze using the G2934Y recipe with added Mason stains.

Context: , Ceramic Stain

Tuesday 7th July 2026

Retro glaze chemistry calculation - 1980

A 1980 desktop Insight report

I did this batch-to-formula glaze chemistry calculation to help a potter with a transparent cone 10 glaze for a Plainsman P500 (a 25x4 porcelain). This version of Desktop Insight ran on the TRS-80 Model I and III, they were the first popular consumer microcomputers for business (outselling Apple 5-to-1). Notice the report uses capital letters; the machines did not support lower case! The dot matrix printers of the time lasted forever on an ink ribbon. Fanfold paper fed from a box, I could tear off only as much as was needed for a report. Boot time was less than 5 seconds. Here is what is amazing: In 2021 I found this same recipe in my Insight-live account (the green screenshot)! The results are a little different; I had the chemistry of talc wrong in 1980. Through the years, I wrote code to migrate from one system to another, and eventually it got to Digitalfire.

Context: Glaze Chemistry Basics -.., Glaze calculation in the.., Digitalfire Insight 4 1.., Digitalfire Insight in 1984.., Digitalfire Insight

Monday 6th July 2026

A test mug I made back in 1981

It has a story that goes back to early Digitalfire

This is a cone 6 oxidation test mug I made in 1981. The speckling in the glaze was made by adding iron stone concretion particles. But this also has a story. Most potters at the time were firing cone 10R or low-temperature, cone 6 electric stoneware was a new development. Note the incised code number: "81-R-5". Digitalfire data archival was already well underway on my TRS-80 computers. The base also has a "60#" marking. I was trying a finer 60 mesh particle size to alleviate the glaze pinholing problems that plagued Plainsman customers at the time (their products were made at 42 mesh and kilns did not have controllers that enabled drop-and-hold or even hold-at-temperature firings that are used now). Pinholing was one of the first glaze problems that I studied; many glaze chemistry projects, using my new Desktop Insight, were aimed at making glazes having melts of lower surface tension and higher melt fluidity (using frits).

Context: I once tolerated this.., Tony Hansen's Pottery Gallery.., Tony Hansen, Tony Hansen pottery what.., Hansen, Glaze Pinholes, Pitting

Friday 3rd July 2026

Technicians study the physics of Yixing clay

To determine the ideal firing temperature

The clay here is called jiani, it’s found in various layers along with other yixing clay (but not used for teapots). The translation of this video screen capture (below), provides a fascinating insight into how they judge the suitable temperature at which to fire. First, technicians measure the porosity and firing shrinkage over a range of temperatures, likely looking for a firing "sweet spot". Notice shrinkage reaches a maximum at 1100C, then drops off as the clay begins to expand. But this is not the only thing considered. Notice, in the comments, that they are also looking for "surface luster" (which is not found). They also comment about a "dull sound" and "crisp/clear sound" (so they must create a sounding vessel of some sort). They also break a fired piece and comment of the nature of the cross section, revealing something else interesting: The clay holds on to a dense cross section for 100C degrees after reaching maximum fired shrinkage.

Temp Shrinkage Porosity Visual & Physical Characteristics
1000°C 8.3% 7.7% Orange-yellow, dense cross-section, relatively dull sound, matte surface (no luster).
1100°C 16.1% 4.2% Deep purplish-red, dense cross-section, crisp/clear sound, matte surface (no luster).
1150°C 14.8% 3.9% Purplish-red with a hint of brown, dense cross-section, crisp/clear sound, matte surface (no luster).
1200°C 14.7% 3.0% Brownish-red, dense cross-section, crisp/clear sound, matte surface (no luster).
1250°C 10.9% 2.6% Brownish-red, iron-rich melt-holes on the surface, dense, crisp/clear sound, produces bloating/bubbles.
1300°C 3.5% 3.4% Brownish-red, iron-rich melt-holes on the surface, severe deformation, has a relatively large amount of bloating/bubbles.

Context: This terra cotta clay.., How to decide what.., Yixing Teapots

Friday 26th June 2026

Yixing craftswomen at work

The Yixing teapot craftsmen appear to break all the rules and yet produce impossibly delicate and symmetrical pieces. Hao-Tong Yan, one of those craftsmen, and I have been trying to understand the technical reasons for how this amazing craft is possible. It turns out not to be magic, but actually a highly evolved understanding of a very unusual material. Here are some of the things that we are coming to understand (which is making it possible to create a facsimile of the clay in North America).

-The clay is not highly plastic; the workability comes from surprising places.
-The clay has impossibly low water content, yet can be formed.
-Craftsmen flatten the clay with a mallet, instead of rolling it, yet it does not stick to the board.
-Sections are simply glued with slip, yet they hold.
-The clay burnishes, yet is not smooth.
-Fired ware is smooth, yet the soft clay appears sandy.
-The fired surface is glossy, yet there is no glaze.
-The fired clay appears super dense yet does have porosity.
-The Yixing ore can have the appearance of being like rocks, yet they make a workable clay body from it.

Context: Yixing Teapots

Thursday 25th June 2026

GoFundMe Refund In Process

Thanks again to the potter who set this up and stopped it. This is my first exposure to a fundraiser; it is amazing what is possible. I was obviously excited about how it could accelerate my succession plan, but realized that Digitalfire has to remain completely a volunteer labour of love. I was worried about his reaction to cancelling this, but he is on board. The refund process began on June 27.

The succession plan is unchanged, click to see more

It is a code-museum (because I started around 1982 using dBase II). That being said, about 5 years ago I converted Digitalfire to an API fronted database that endpoint code calls to create pages on the fly. This is coupled with a backend custom content management system that interacts directly with the database; thus, no pages are edited, only DB records. But a lot of old code is still there. Here are the current priorities:

  • The code is only partially on GitHub (required for team development and code analysis). I am refactoring it to adhere to PSR-4 coding standards (this is a rote process that I have been working on for about 6 months). As soon as I am ready, or before, I'll need help to write or improve the unit testing.
  • Document and publish the API to enable coders to create products that use the data from the API (e.g. machine translation). Explore refactoring in Python or JS/Typescript.
  • An MCP server, in Typescript or Python, to respond to queries from answer engines, thus supporting AEO.
  • Front the content management system in a secure way so that multiple people can start contributing and error checking. Convert to API access.

Other priorities that recent events indicate:

  • Implement a hashtagging system in the people database (for the newsletter) so that any who offer help can be classified and not forgotten.
  • Adopt Creative Commons licensing to enable students and teachers to quote and use without fear of copyright issues.
  • Document testimonials well to be able to demonstrate harm if the service is ever threatened.

As noted above, at the beginning of Covid, I redesigned Digitalfire as a client/server page generation system. An API, fronting the database, can run on one server while the page-generator can run on another server (by querying the API). There is a lot of caching. The content management system is custom-written for the information hierarchy; it runs on the same server as the API.

Please don’t believe twisted interpretations of the events during the latter part of June. You have seen me share freely for well over 4 decades. Please rely on my record rather than misinformed recent postings. I don’t rebut or flame people on social. But it does hurt when they say things that are totally against my character. As soon as I learned a GoFundMe had been started, I posted the succession plan. But it was behind a disclosure triangle and people were not opening it (see above). I have been working on item 1 for a year already; hopefully, 6 more months will do it. It shocks me how big and complex Digitalfire has become!

Saturday 20th June 2026

Resolution Achieved!

If you already sent, get 4 years Insight-live credit

I posted this on June 19.

I need goodwill with Plainsman. I know you have been passionate about this whole affair in the past few days. I underestimated how much. Some were so passionate that they have caused trauma with Plainsman staff, we must undo that. Having goodwill with the company I partnered with to make Digitalfire is so important and will make me so happy. We both "pulled the dragon's tail" over misunderstandings.

I consulted Plainsman before posting this, and they requested I add: Here is the biggest one: Digital Fire is not at risk and never was from Plainsman.

I need goodwill, especially if you put staff under stress, and you can help me get it. My first idea was to fill their office with hundreds of bouquets of flowers, but now I realize that's too much environmental impact. I'll credit you 4 years of Insight-live if you already did (this statement was added after I realized this was not a wise request).

Friday 19th June 2026

Thank you sooo much!

Thank you to the hundreds of messages I am getting every day for support. Yikes. I can assure everyone I am not retiring; I am just getting started. I cannot believe the offers of help I am getting from coder/potters, lawyers, negotiators, designers, etc; there are so many of them. And how many countries. This is amazing. Messages from countries where potters and industry rely on Digitalfire because ceramic fabrication information is either kept highly secretive, despite a large manufacturing sector, or simply doesn't exist, really moved me. And an offer from a Google engineer to help. Or even a suggestion to move the dark web! Information on how to change licensing to clarify reuse. Advice from human rights experts on the importance of freedom of information. How to organize team coding. How to automate translation. Many offered physical server resources and hosting. Others offered new tools they have developed to integrate into Digitalfire. And so much more.

Wednesday 17th June 2026



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