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Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details D’source 2 Digital Learning Environment for Design - www.dsource.in Design Resource Introduction Dhokra Metal Casting, Adilabad is one of the main cities of Telangana state. It has an elevation of 264 metres. The district is surrounded Adilabad - Telangana by Nizamabad and Karimnagar districts of Telangana towards the south and Nanded, Yavatmal, Chandrapur and An Ancient Bell Metal Craft Godchiroli districts of Maharastra towards the west, east and north respectively. The district is well connected to by rest of India by road transport as National Highway 7 passes through this region. Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru The origin of this region dates back to the reign of Asaf Jahi dynasty. It was the northern district of Nizam state founded by Nizam-ul-Mulk in the Deccan region. However Adilabad was ruled by many dynasties like Mauryans, Satavahanas, Chalukyas, Qutub Shahis and Asaf Jahis. Thus the name Adilabad was derived from its erstwhile Is- lamic ruler of Bijapur, Yusuf Adil Shah. But the original name of this region was Edlabad during the rule of Qutub Shahis later it was changed to Adilabad. Hence Urdu was the official language of Adilabad and since 1956, as this Source: region became a part of Telugu linguistic state, the language Telugu gained prominence and became the official http://www.dsource.in/resource/dhokra-metal-cast- language of Adilabad till today! ing-adilabad-telangana/introduction However the current culture of the district witnesses the multicultural society, where Telugu, Marathi, Bengali, Malayali, Rajasthani and Gujarati people are living in harmony. Adilabad has a population of 1,17,167 according 1. Introduction to the census held during 2011, in which males constitute 59,448, females constitute 57,719 and the population under the age group of 0-6years constitutes 12,993. This place is well known for its historical temples, shimmer- 2. Tools and Raw Materials ing waterfalls and magnificent monuments. The other attractions of this place are Kuntala waterfall, Shivaram 3. Making Process wildlife sanctuary, Kawal wildlife sanctuary, Pochera falls and Kerameri ghat roads. Adilabad is also recognized as 4. Products the hub of cotton mills and it is also famed for dhokra metal casting practiced by Ojha metalsmiths of this region. 5. Video Dhokra is an ancient bell metal craft practiced in various places of the country. It is well known craft of Chattis- 6. Contact Details garh, Odisha, West Bengal, Jharkhand and Telangana. The workmanship and the skill of artisan community vary in different states. Dhokra is a tedious job made using the procedure of lost wax technique while casting the metal. This craft combines wax technique with the metallurgical skill to create artifacts of distinctive beauty. Dhokra is a very labour intensive as it consumes minimum of 4-5 days to make a simple piece of work whereas the complicat- ed designs could take up to 2-3 weeks’ time. These dhokra metal artifacts are usually made traditional but on de- mand the contemporary designs are also made. Characteristics of these dhokra metal objects comprise slender and elongated figurines, folk lamps, household articles like measuring bowls and lamps. The uniqueness of these artifacts is that the object is entirely handcrafted with the final product that has a different texture depending on the wax strips and these relics do not have any joints. D’source 3 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/introduction
Dhokra is the traditional folk art which is followed Master artisan Mr. Indrajeeth. 1. Introduction since Harappa and Mohenjo daro period. 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Molds of different size and shape used in dhokra Family involved in dhokra casting. casting. D’source 4 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/introduction Pure bees wax is drawn into small thread to make various designs.
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Female artisan helping the master artisan in burning Female involved in filing and polishing the product. the furnace. D’source 5 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/introduction
Master artisan explaining about wood (sunrise). 1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Artisan making designs on mold using bees wax. D’source 6 Digital Learning Environment for Design - www.dsource.in Design Resource Tools and Raw Materials Dhokra Metal Casting, Adilabad - Telangana Tools and raw materials used for Dhokra Metal Casting are as follows: An Ancient Bell Metal Craft • Anthills Mud - Mud is the core material that is used for making the first model of the final product. by Prof. Bibhudutta Baral and Rakshitha • Water - Water is used for kneading mud and cow dung. NID, Bengaluru • Cow Dung - Cow dung is mixed with mud to make the model.
• Wax Threads - Wax threads are wound around the clay model.
Source: • Charcoal - Charcoal is burnt in the furnace to obtain high amount of heat. http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/tools-and-raw-materials • Brass - It is one of the core substances that are used for making dhokra metal products.
• Wood - Wood is used for firing purpose. 1. Introduction 2. Tools and Raw Materials • Furnace - Furnace is used for baking the clay model. 3. Making Process • Graphite Container - Graphite container is used for arranging and melting metal (brass) crucibles. 4. Products 5. Video • Hammer - Hammer is used for removing the clay mould. 6. Contact Details • Customized Tool - It is used while rendering the required design.
• Sand - It is mixed with clay.
• Salt - It is added to metal crucibles while heating the metal.
• Hacksaw Tool - This is used for cutting out the extras of the metal product.
• File Tool - This tool is used for polishing purpose.
• Big Sized Brush - This brush is used for dusting and cleaning of the clay particles.
• Furnace - It is used for melting the metal and baking the clay moulds. D’source 7 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/tools-and-raw-materials
Coal is put in furnace to gain more heat. Brass is one of the main raw material 1. Introduction used in dhokra. 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Brass is melted by putting them in Cutting plier and hacksaw blade is used to cut the extra piece of the crucible. casting. D’source 8 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/tools-and-raw-materials
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Heated molds in furnace is removed using different Wire brushes are used to clean the sand from the types of pliers. casting. D’source 9 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/tools-and-raw-materials
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Different types of files are used to clean and polish Wax threads are drawn using pichikri with different the casting. diameter of button. D’source 10 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- Using bees wax required design is sculpted. Different sizes of hammers are used to break the molds. ing-adilabad-telangana/tools-and-raw-materials
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Wood is burnt in furnace to melt the brass. D’source 11 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/tools-and-raw-materials
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Different types of customized tools made out of Anthill soil is used to cover the wax layer. wood to sculpt on wax model. D’source 12 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/tools-and-raw-materials
1. Introduction 2. Tools and Raw Materials Different types of molds are used to make casting in required design. 3. Making Process 4. Products 5. Video 6. Contact Details
The brass and wax are melted in furnace. Mixture of cow dung and sand is used to make molds of different size and shape. D’source 13 Digital Learning Environment for Design - www.dsource.in Design Resource Making Process Dhokra Metal Casting, The metal artifact that has to be made is initially prepared in clay. The preparation of this clay is made by mixing Adilabad - Telangana anthills mud with cow dung in an appropriate ratio. This mixture is kneaded thoroughly with water and acquired An Ancient Bell Metal Craft the desired consistency. Further using this mixture of clay, the core model is made. On the next level the pure by form of clay is applied to render the fine smooth layer. This clay model is further allowed to dry and upon this, Prof. Bibhudutta Baral and Rakshitha the wax threads are wound all around to form a layer and to acquire the chosen design pattern. Further on the NID, Bengaluru wax coating again a layer of clay mixed with sand is applied. Here the sand is used for the tightness of the mix- ture. Further two holes (channels) are made and allowed for drying. These channels are made to pour the liquid metal and to release the air out. Once the clay model is completely dried, a mixture of sand with minimal quan- tity of clay is applied and then the process gets continued by baking the clay - wax model in furnace. When this clay – wax model is baked, the wax in-between the clay layers get melted and oozes out of the opening. Thus the Source: space gets emptied and remains as a hallow space in-between the clay layers. Then the clay mould is taken out of http://www.dsource.in/resource/dhokra-metal-cast- the furnace and the molten metal is poured into the funnel like opening on the upper surface of the mould. This ing-adilabad-telangana/making-process molten metal is acquired by melting the metal crucibles. These metal (brass) crucibles are initially arranged in a graphite container and carefully heated to get the molten metal. A tinge of salt is added to metal crucible while heating it, to obtain the pure form of molten metal and to speed up the process. 1. Introduction Once the liquid metal is poured into the mould, it acquires the shape and pattern of the model eventually, by 2. Tools and Raw Materials taking the impression of the wax model in all its detail. It also gets hardened between the core and the inner sur- 3. Making Process face of the mould. Further it is allowed to cool down completely by dipping the mould in water. It is then slightly 4. Products hammered to remove the burnt mould completely and brushed thoroughly to clean from inner and outside. Then 5. Video it is neatly polished by rubbing the file tool all over the metal product. And thus the finished product is prepared. The whole process carries four days to complete when the objects are created in bulk. As the making of clay mod- 6. Contact Details el acquires a day time, winding of wax threads to the clay model takes another day’s time. While the baking and further process requires at least of one or two days to prepare the end product. D’source 14 Digital Learning Environment for Design - www.dsource.in
Design Resource Flow Chart: Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details D’source 15 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Initially cow dung is mixed with sand to make clay. Required design is made using clay and kept under sunlight to dry. D’source 16 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- Bees wax is softening by heating in furnace. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Bees wax is inserted into pichkari and pressed to Wax threads are drawn using pichkari. make threads. D’source 17 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- The thread is winded around the mold. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Requires designs are made on the wax. A thick design layer of wax is winded at the edge of the mold. D’source 18 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Two pieces of mold are attached together using Designed handle is fixed on the mold. a mass amount of wax. D’source 19 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- A bird design is place on the top of mold to make ing-adilabad-telangana/making-process it decorative.
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Anthill soil, sand and water is mixed to make clay. Circular designs are fixed to the mold. D’source 20 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- Clay is covered all over the wax layer. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
The clay is applied over the designed wax layer. Holes are made for melted wax to drain out. D’source 21 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- A piece of wax is placed at the entrance of the hole ing-adilabad-telangana/making-process in order to avoid blockage.
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
The mold is kept under sunlight to dry. Another layer of clay is applied on the mold. D’source 22 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- Little salt is added with brass. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Old brass is made into small pieces and put inside Crucible is placed inside furnace to melt the brass. crucible. D’source 23 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- Furnace is covered with wood. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
The mold is place above the wood to melt wax. The mold is fully covered with pieces of tiles and metal bowl. D’source 24 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- Brass is heated for almost two hours to melt. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
The mold is place on sand after melting process. Melted brass is poured inside the mold to attain its shape. D’source 25 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- The brass is cooled down by submerging in water. ing-adilabad-telangana/making-process
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
The extra piece on the casting is removed. The mold is broken to take the out casting. D’source 26 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/making-process
The sand on the casting is removed using different tools. 1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Beautifully made lamp. D’source 27 Digital Learning Environment for Design - www.dsource.in Design Resource Products Dhokra Metal Casting, The products made as per the requirement of the customers. Though many a times the products are made out Adilabad - Telangana of single metal sometimes when needed using five alloys (Panchaloha) the final products are prepared. Artisans An Ancient Bell Metal Craft usually take up only order based work with an advance. Some of the products that could be found here are: Lord by Buddha, Birds, Designer diya, Idols of gods and goddess, Animals, Reptiles like turtles, Jingles, Wall hangings, De- Prof. Bibhudutta Baral and Rakshitha signer bowls and etc. Typical dhokra artifacts usually cost between INR.300-500. NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/products
1. Introduction 2. Tools and Raw Materials 3. Making Process Adha-maf (Indian language) is a cup to keep Traditionally made peacock designed lamp used in olden 4. Products offerings for god. days. 5. Video 6. Contact Details
Beautifully made traditional dhuparna Portray of different kinds of animals made out of brass. (Indian language) lamp. D’source 28 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/products
Idol of turtle with detailed design. 1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Small bells used to tie around the neck of cow, ox etc. Traditionally made bangles. D’source 29 Digital Learning Environment for Design - www.dsource.in
Design Resource Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/products
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details
Beautifully made idol of lord Buddha in blessing Idol of lord Buddha meditating on turtle. posture. D’source 30 Digital Learning Environment for Design - www.dsource.in Design Resource Video Dhokra Metal Casting, Adilabad - Telangana An Ancient Bell Metal Craft by Prof. Bibhudutta Baral and Rakshitha NID, Bengaluru
Source: http://www.dsource.in/resource/dhokra-metal-cast- ing-adilabad-telangana/video
1. Introduction 2. Tools and Raw Materials 3. Making Process 4. Products 5. Video 6. Contact Details Dhokra Metal Casting - Adilabad D’source 31 Digital Learning Environment for Design - www.dsource.in Design Resource Contact Details Dhokra Metal Casting, Adilabad - Telangana This documentation was done by Professor Bibhudutta An Ancient Bell Metal Craft Baral and Rakshitha at NID, Bengaluru. by Prof. Bibhudutta Baral and Rakshitha You can get in touch with Professor Bibhudutta Baral at NID, Bengaluru bibhudutta[at]nid.edu.
You could write to the following address regarding sug- gestions and clarifications:
Source: Key Contacts: http://www.dsource.in/resource/dhokra-metal-cast- Shri. Indrajeet Ojha, Senior Craftsman ing-adilabad-telangana/contact-details Adilabad Telangana Cellphone: 96529 52224 1. Introduction Helpdesk Details: 2. Tools and Raw Materials Co-ordinator 3. Making Process Project e-kalpa 4. Products R & D Campus National Institute of Design 5. Video #12 HMT Link Road, Off Tumkur Road 6. Contact Details Bengaluru 560 022 India.
Phone: +91 80 2357 9054 Fax: +91 80 23373086 Email: dsource.in[at]gmail.com