The process of creating a copper sink begins long before the craftsmen approaches the smooth blank canvas an unhammered copper sheet offers.

Copper is one of the most abundant minerals on the earth’s surface, however, it is normally found trapped in iron sulphides, and needs to undergo a complex refining process to separate the metal from the ore. When the process begins, the ore contains just 0.6% copper, however, after being smelted, and/or subjected to electro-refining, the copper eventually reaches a purity level of over 99%, the level required to created high quality copper sinks.

Fortunately, copper is one of the most easily recycled elements on the planet, and large quantities of copper is returned to use by melting down unwanted plumbing and wiring. The unused copper created when producing sinks, such as the scrap created by the hole for the waste outlet, can also be melted down and reused

Once the copper has been refined, it is formed into large sheets, which vary in thickness according to the demands of the design, and the quality of the product. Sinks are generally made from 14 to 18 gauge copper, with the lower number being the thicker, more substantial material and robust the sink. For this reason, kitchen sinks tend to be made from thicker gauge copper than bathroom basins.

High quality, handmade copper sinks are produced by first heating a sheet or disk of copper over an open fire, such as you would expect to see in a blacksmiths, and then hammered by hand to create the perfect shape. Heating makes the copper malleable, making it easier to work with, and the copper will be heated on several occasions to ensure the sink forms a perfect shape. The hammering creates a stylish pattern that it is impossible to replicate exactly, making each sink as unique and individual as the person who buys it.

The colour of the finished item depends on the number of times it is heated and cooled during production, and can vary from a rich copper red to a deep copper brown. Once the sink achieves the perfect shape, the edges are smoothed, and the waste outlet punched through the metal. Then, depending on the finish required, the sink undergoes a final heat treatment to achieve an even patina.

It is not unusual for a handcrafted copper basin to take a full day to produce, and some kitchen sinks can take one man up to three days before they are perfected. The sinks are then rigorously inspected to ensure that there are no major flaws or imperfections, and the finished product is carefully packaged ready for delivery to the customer.