The Fedoskino artisans who learned the art of painted miniature lacquer boxes from the Germans use pure wood pulp to make their papier-mâché. Whether the process was a German discovery or did it evolve in the Fedoskino factory is not known, though the process of manufacture is in strict compliance with the original formula. But the use of pure wood pulp makes the papier-mâché harder, stronger and can withstand any climate change or environmental conditions. In spite of the Russian papier-mâché seeming delicate and fragile, the ingredients used and the process involved infact make it extreme durable and functional, almost like wood. In addition, as papier-mâché, produced for a Russian miniature lacquer boxes have no grain, authentic Fedoskino lacquer box produced using the traditional techniques and materials will never warp or crack due to climatic conditions.
Russian lacquered
The production of a Russian lacquered box is a time consuming, multi-stage process that involves skillful artisans, painters and artists of through the many stages of the process. The pure wood pulp papier-mâché is made into sheets that are then cut to the required length and size. The cut pieces of same sizes are glued together and pressed until it becomes one hard piece. While the glue is still wet, it is pressed to take the shape of the form it is pressed up on and left to dry for a month; sometimes a little less. Boxes may be round, rectangular or square shapes. The dried pieces that have taken the shape of the box are then soaked in a special bath of linseed oil and baked in an oven at high temperature.
Once out of the oven, it is cut to the required size and the sides and edges Businessacademy1 smoothened out using a sanding machine. The dried plates of papier-mâché are glued to the lid and the bottom of the body and any uneven projections or deformities are sanded until there are no blemishes. Custom-made hinges are attached to the box and these keep the lid and the body together. Imperfections and cavities are cleared out by puttying and several layers of primer applied on top of each layer that is dried in special drying cabinets. The primer layer is sanded to perfection before several layers of black lacquer is applied to the outside and red to the inside, one layer on top of every dry layer. It is now ready for the artist to take over.
A sketch is made on to the top layer using chalk and the chalked area is coated with an aluminium powder base or gold leaf or mother-of-pearl. This creates an impermeable layer for the paint to seep through and the first layer of paint is applied over the sketch, varnished and dried. Once dry, the next layer of painting is made that would involve more detailing, lacquering and drying as before. The final layer of paint brings out all the highlights and is similarly lacquered and dried. The sides of the lid and the body are then decorated with gold leaf or metal foil and is coated with several layers of transparent lacquer, dried and polished to a mirror like sheen. The whole process of production will take a minimum of 4 to 6 months to complete and then it is packed and shipped for retail sales.