Our handmade thin brick tiles are crafted in Pennsylvania using traditional methods and antique molds, giving each tile a unique character and lasting strength. From raw clay to final firing, our artisan process ensures timeless beauty, structural durability, and a truly authentic brick appearance. Here's how we bring our historic-inspired tiles to life, one batch at a time.
At Inglenook Tile Design, every thin brick tile is made by hand using time-honored techniques and the finest natural materials. What began as a homegrown project — firing bricks in a backyard kiln — has grown into a partnership with skilled artisans who share our love of clay, craft, and timeless design. Here’s a look at how our tiles come to life:
1. Clay Preparation: We start with high-quality clay, delivered in bulk and carefully blended. The clay goes through a pugmill — a machine that mixes, de-airs, and shapes it into slabs (called "charges") ready for molding.
2. Molding by Hand: Each slab of clay is cut to size and laid over trays filled with custom polyurethane molds. Before pressing, we add finishing touches like powdered clay or wood ash for subtle surface variation. The slab is pressed into the mold using a slab roller, forming the tile shape and adding a textured back to ensure strong adhesion during installation.
3. Trimming & Recycling: Tiles are trimmed with a circular blade (often a repurposed pizza cutter), and any excess clay is recycled — often on the same day — to reduce waste. Our process ensures very little material loss.
4. Drying: Freshly formed tiles are set on racks and dried under fans for up to 48 hours, depending on the season. This slow drying step is crucial, as the tiles are most fragile right before they fully dry.
5. Sanding & Quality Check: Once dry, each tile is inspected and the edges are sanded by hand. We ensure there are no sharp edges or surface flaws — because we believe every tile should be beautiful and barefoot-friendly.
6. Firing in Gas Kilns: Tiles are loaded into large gas-fired kilns. Each kiln has unique hot and cool spots, which create the natural color variation our customers love. The tiles are fired for at least 30 hours, then cooled slowly to prevent warping and ensure durability.
7. Final Inspection & Packing: Once cool, tiles are checked one last time before being packed into boxes, loaded onto pallets, and shipped across the country. Each order is carefully coordinated by our team to ensure safe delivery and happy customers.
Why It Matters: Because every tile is handmade and fired with care, no two are exactly alike. This gives your space an authentic look that can’t be mass-produced. It’s why designers, homeowners, and preservationists choose Inglenook Tile Design: for character you can feel, and craftsmanship you can trust.
