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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

  • Thanks for all you do for ceramics!
  • First, let me thank you for creating such a wonderful, informative, and comprehensive site. I know that I will spend many a long hour pouring through your pages.
  • I Just wanted to say thank you for all of your research! every question i ask google about ceramics ... POP there is your artical with the answer. !
  • After perusing your site for some time, I am really getting the sense of what a valuable resource it is. Thank you for it.
  • When my group of potters are pressed to improve our glazes they say if the old way is not broken yet why don't you buy yourself some kind of a kit to play with new glazes and then we can make it for everyone. You got to be kidding I say to myself. Anyway, your website will help me help the group out of some old and boring glazes if I can see forward enough. Thanks for all this important info, I can't believe this website is here!
  • This is the first time I have used this site, and I am impressed. I use HyperGlaze software on my PowerMac with pleasure, but this data site is an up to date boon. Congratulations!
  • Your sight ROCKS.
  • I want you to know how much it means to me to have you help with my questions. I have been doing pottery for over 20 years and never new this stuff. I feel so responsible for my glazes leaching and stupid to not have known, and the stress or waiting for the lab test results has been eating me up.
  • Your resources are truly amazing and as an ex electronic engineer (now a potter), I really am impressed with your analytical approaches. Your site is almost a complete college level course on pottery (less the throwing & handbuilding). Thank you for your wonderful contributions.
  • I have almost finished your book, THE MAGIC OF FIRE. I am enjoying it very much. I am sure that this is a book that I will reread many times.

What people have said about Insight-Live

  • Your site is a fantastic resource, I recommend it to everyone.
  • Superb. Very interesting study (about frit melting behaviour). Wow. What a patient effort!
  • I love your software and I really appreciate you being there when I need help. Keep on being amazing. I am still enjoying insight every day. You were right - having it in the cloud is a huge advantage. Your service to potters worldwide is extraordinary. It strikes me as a remarkably generous and altruistic project, and the value it brings to our community is immense.
  • I'm definitely a fan, I can see how hyper-focused you are on ceramics and it's nice to learn from you, but also I like the intensity, you've been doing this for decades. I'm kind of curious if you're autistic too, your level of focus is unusual for neurotypical folk. Anyhow, thank you for your research and hard work. They have benefited me a great deal, and a lot of the things I've learned from you I haven't seen elsewhere.
  • First of all I'd like to convey all my gratitude and an immense thank you for all the work and research that you make available for the ceramic community, it is invaluable.
  • I am writing to express my sincere gratitude for the incredible work you have done over the decades. A large part of my own journey and understanding as a ceramicist is built upon the knowledge I was able to learn through your work at Digitalfire and Insight-live. The value of this technical foundation is truly immeasurable, and I wanted to let you know how much it has meant to my development in this craft. Thank you for everything you have contributed to the joy and science of ceramics.
  • Yet again, you provide a quick answer not easily found elsewhere (a bowl was befuddling me with wall cracks that never made it to any edges.)
  • I am a big fan of your work. I want to thank you for being there when I have needed and hopefully I will be able to carry on without much input from you. I will be renewing my subsrciption soon and I extol the virtues of the program (and now the Cloud version) to everyone that will listen.
  • I have been using Digitalfire for 10 years to help me understand and develop glazes and clays and I can’t thank you enough for all of the efforts you have put into this. You are a huge resource and thank you!
  • It’s been now a couple of weeks that I learn everyday with you and your amazing project. I find your way of tackling experiments clear, practical and smart. I wish more quality content like yours was available on all of my interest topics!

Monthly Tech-Tip from Tony Hansen

I will send practical posts like these (from thousands I maintain). No ads or tracking. The first email will provide one-click unsubscribe. Signup is being email-bombed by bots. For now, please subscribe inside your insight-live.com account.


Blog

Copper is not just a pigment

It can be a powerful flux

The base recipe is GA6-C (80% Alberta Slip, 20% Frit 3134, 4% rutile). That recipe is stable; it does not run unless applied very thickly. What did it take to make it run like this? A 2% addition of copper carbonate! Even at this low proportion, it is really intensifying melt fluidity, producing a pleasant green even on a red-burning body (which is not easy in ceramics). Using the parent GA6-C as a catch glaze, this could be made safe on vertical surfaces. However, there is a caution. Having only 2% copper would not destabilize a typical glaze (make it leachable). But phase separation is still occurring because the base contains significant rutile. That means the phases are copper-bearing. Another red flag is that the copper has a greater-than-expected impact on the melt. Third, commercial variegated copper glazes can even leach in acids. So, testing would be needed for use on functional surfaces.

Context: Copper Oxide Black, CuO, 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

1988 Insight logo reimagined by Gemini

The old logo is from the late 1980s and was used to promote Desktop Insight at trade shows and to advertise it in magazines and later on the early internet. It was done in Aldus Freehand, an early competitor to Adobe Illustrator. Vector graphic illustration was revolutionary at the time. Amazingly, many artists even today do not know what vector graphics is, they are still working with "pixel pusher" apps like Photoshop.

I asked Gemini how it made this, and it said: "I started with a blank canvas of random digital noise (a chaotic grid of pixels) and gradually refined that noise over multiple steps based on your prompt and the layout of your original image. There was not need for a vector stage; the smooth transitions, glowing embers, and soft gradients are baked right into the generation process from the very beginning."

Context: Here is what digitalfire.., Digitalfire Insight

Saturday 13th June 2026



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