Process for Assembling and Mending Multi-Piece Ceramic and Pottery Breaks
Reconstructing pottery made of many broken segments is more challenging than it appears at first glance. Each piece influences the next, so even a small mismatch in angle, height, or tilt can start a chain reaction that throws the entire form off. This is not a random process; it is a structured method that requires intention, planning, and adherence to proven techniques. The objective is not simply to glue fragments together but to restore the original geometry as closely as possible. Clean seams, correct balance, and accurate projection all depend on thoughtful sequencing, careful preparation, and an understanding of how each segment interacts with the larger form. Working patiently and using physical forces like gravity to your advantage will greatly increase your chances of preventing cumulative errors. The guidelines below outline the most reliable methods for maintaining correct alignment during multi-piece assembly.
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1. Avoid Forcing Tight Angled Fits
Avoid creating conditions where a later segment must be inserted into a space tighter than ninety degrees. If a piece must be twisted, wedged, or threaded in, the risk of breakage or misalignment rises significantly.
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2. Work in Clear Sub-Sections
Treat each sub-section as a small, self-contained project. When two sub-sections meet, the shared edge must
be straight, clean, and uniform. Avoid boundaries that interlock like woven fingers. A flat, continuous edge
ensures the next segment seats properly.
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3. Use Gravity to Your Advantage
Always perform a dry run before applying adhesive. Position the lower segment so the one above it balances
naturally without support. When the geometry is stable and the projection aligns naturally, apply adhesive.
Gravity should help hold the assembly, not fight it.
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4. Use Temporary Supports as Needed
Certain angles will not hold on their own during curing. Use clay, painter’s tape, or removable low-temperature
hot glue to stabilize awkward positions. These temporary supports prevent shifting while the adhesive sets.
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5. Prevent Error Buildup
Apply adhesive in very thin layers. Excess epoxy between joints creates height differences or tilt that
accumulate as the assembly grows. Thin adhesive layers maintain clean alignment and prevent cumulative distortion.
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6. Assembly as One Continuous Process
Many epoxy systems remain adjustable for several hours during the early curing stage. Some formulations allow slight angle correction when warmed gently to 140-180°F (60-82°C) within the first few hours. This brief window permits small alignment adjustments without compromising long-term bond strength, provided the piece is handled carefully and corrections are made gently.
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7. Final Pieces Fit Issues
The final pieces often feel slightly tight because of slight height built up or narraow angel was unevedable or alignment changes earlier in the process. Removing a small amount of material with a fine diamond bur may be necessary.
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8. Recommended Tools and Materials
A reliable setup improves precision and reduces alignment errors. Useful tools include a high-quality two-part epoxy (we typically use a 5-minute set time), micro-spatulas, 91 percent alcohol for cleaning break edges, fine diamond burs, bright LED side lighting, painter's tape, clay for temporary supports, and a magnifier for inspecting seams. In most cases, we use containers filled with PVC or resin pellets to hold broken segments in place. This allows us to position pieces using gravity without needing temporary bonding (see image on right). Where to get supplies
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9. Surface Preparation Before Assembly
Clean break edges with alcohol to remove dust and skin oils. Do not use water for cleaning, since it takes a long time to dry and any remaining moisture can compromise the bond. Pre-segregate the broken pieces into logical sub-sections and perform a dry run for every segment. Inspect and remove any small ceramic fragments or debris that could cause spacing errors. Have all necessary tools and materials within reach before you begin. Proper preparation dramatically improves final accuracy and prevents unnecessary delays, especially when working with a quick-set epoxy where working time can run out quickly.
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10. Choosing the Correct Assembly Sequence
Begin with the largest, most stable structural area. Avoid starting with isolated fragments. Build outward
from a stable anchor so each new piece benefits from the support of the previous ones. Proper sequencing
prevents stress and distortion.
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11. When a Piece No Longer Fits
Do not force a misfitting fragment. Recheck adhesive thickness, confirm no micro-chips are missing, verify that an adjoining segment has not rotated slightly, and only remove material with a diamond bur as a last resort.
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12. Curing Time, Handling, and Safety
Handle the object carefully during set time. Avoid putting pressure on newly joined areas until the epoxy reaches full cure. Work in a ventilated area, and do not move the assembly prematurely, since even slight movement can cause subtle misalignment. Revisit the piece periodically during the early set period to check whether any alignment has shifted and make gentle adjustments if the epoxy still allows it.
Cure time can vary from the manufacturer’s specifications. The warmer the room, the faster the epoxy will set. A cold environment below 68°F (20°C) can drastically slow curing. We typically work at a room temperature of 70-72°F (21-22°C) to maintain predictable set and cure times. To stay consistent, we use a timer to remind us when the next segment can be added safely.
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13. Alignment Tips
Use a bright side light or a UV light to catch seam shadows that reveal misalignment or areas lacking surface continuity. After removing excess epoxy with a cotton rag dampened with 91 percent alcohol, feel the transitions with your fingertip to detect even the slightest steps or unevenness. This combination of visual and tactile inspection helps ensure clean, accurate alignment.
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14. Common Mistakes to Avoid
Rushing the process, using too much epoxy, skipping dry fitting, allowing joints to set before checking alignment, and ignoring cumulative error are the most common causes of poor outcomes.
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Additional Resource
For a visual demonstration, see Lesson #3 - click here. It shows how to keep cemented pieces stable while curing.
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