✅ THE PRODUCTION PROCESS OF TILE TEXTURES FROM A TO Z
☑️ Introduction
The production of ceramic tiles that reproduce natural textures is a growing trend in the ceramics industry. This process allows for the creation of tiles that faithfully imitate natural surfaces such as tree bark, fabric textures, and natural stones, offering a realistic aesthetic and a unique appeal.
Advanced technology and innovative production methods are key to achieving these results. In this context, Cielle is positioned as a leader thanks to its high-precision engraving solutions and the production of large-format matrices.
☑️ Texture scanning and digitization process
The first step in creating ceramic tiles with natural textures is scanning the surface to be reproduced. This is done using high-resolution laser scanners that capture every detail of the surface with micrometric precision. The scanning process involves several phases:
☑️ Surface preparation: the natural surface is cleaned and prepared to ensure that all details are captured without interference.
➡️ Laser scanning: using 3D laser scanners, the surface is digitized. These scanners emit a laser beam that detects depth variations and surface characteristics, generating an accurate three-dimensional model.
➡️ Data processing: the collected data is processed using advanced software to create a detailed digital model. This model faithfully represents the natural texture and can be modified and optimized for mold production.
☑️ Mold creation
Once the digital model is obtained, the mold creation phase begins. Molds are made using specific materials that guarantee resistance and precision.
Cielle uses RFS (Laminated Phenolic Resin), which offers excellent mechanical properties and thermal resistance. The mold creation process includes:
➡️ CAD design: the digital model is imported into CAD software for detailed mold design. This step includes optimizing the dimensions and defining the technical characteristics necessary for production.
➡️ CNC Machining: Using high-precision CNC pantographs, the model is engraved on the chosen material. These machines, like those developed by Cielle, are able to reproduce every detail of the digital model with extreme precision. Numerical control allows for almost complete automation of the process, minimizing human errors and ensuring consistent quality.
➡️ Finishing and quality control: After engraving, the mold is subjected to finishing processes to eliminate any imperfections and ensure its functionality. A rigorous quality control is then performed to verify that the mold meets all technical and quality requirements.
☑️ Tile Production: With the mold ready, the ceramic tiles are produced.
This process involves several phases, including:
➡️ Mixture preparation: the ceramic mixture is prepared by mixing clays, feldspars and other raw materials. This mixture must have a specific consistency and chemical composition to guarantee the quality of the final product.
➡️ Moulding: the mixture is poured into the mould, which transfers the natural texture to the surface of the tile. This process can be performed by pressing or casting, depending on the desired characteristics of the final product.
➡️ Drying and firing: the moulded tiles are dried to remove excess moisture, then fired at high temperatures in ceramic kilns. Firing solidifies the tile and enhances its mechanical and aesthetic characteristics.
➡️ Surface finishing: after firing, the tiles can be subjected to further finishing treatments, such as glazing or polishing, to improve the aesthetic appearance and surface resistance.