Origin of the craft
The Dhokra craft uses the elaborate Lost Wax method of casting metal, which can be traced back 4500 years to the ancient city of Mohenjodaro in the Indus valley civilization. The Lost wax method is said to be the oldest technique of casting metal.
Dhokra craft gets its name from the Dhokra Damar tribe, who are established metal smiths of West Bengal. From West Bengal, the Dhokra work spread to tribal areas in nearby metal-rich states. Dhokra is now found in many regions in India, each region carrying a distinct look.
State(s) it is practiced in
West Bengal, Chhattisgarh, Orissa, Andhra Pradesh, JharkhandAbout the craft
The exquisitely handcrafted Dhokra products involve a tedious process of designing and metal casting. Each piece is unique as one mould can only be used for one product.
Input materialsSoil from the riverbed, Black soil from the fields, Red soil from termite bills, Rice husk, Wax (Beeswax or Paraffin wax)/Resin, Bell metal. The metal proportions used in the alloy and other inputs vary slightly from region to region.
Process
Mould making: The base mould of the product is prepared from a mix of black soil, rice husk and water.
Surface Preparation: Once this base dries, it is covered in fine soil from the riverbed. Emery paper is used to smoothen the mould surface.
Designing: Over this, strips of beeswax or resin are applied to make the designs on the product. This is an arduous process of fine detailing.
Wax or resin is used since it is malleable and ductile. Artisans in different regions use different wax/resin. To reduce cost of wax, some artisans use paraffin wax mixed with coal tar and dhoop (incense).
For making the threads, the wax is first pounded well.
The wax is then pressed through a container. Attached at one end of the container is a metal plate with holes punched in it. This allows the wax strings to be formed in the required shape and size.
The apparatus and metal plates are similar to the ones used for making Chakli's in Indian homes.
Each plate has different shapes punched in it, depending on the artisan's design requirements.
First Layering: After the wax designs are allowed to dry, the product is covered with a mix of coal powder, river soil and water. This layer is pressed onto the wax and hence the design is imprinted onto it. This is allowed to dry. Each new layer is set to dry for around 2-3 hours. Vents are created in the mould, so that the wax can later melt away through it.
Second Layering: Another layer of fine river soil is applied and is left to dry.
Third Layering: Once dry, another layer- a mix of red soil (from termite bills) and rice husk is applied. Larger products have more/bigger vents so that wax and air escapes.
Firing: The product is put in the furnace and the wax melts away, leaving a cavity. The product is taken out of the furnace and is turned upside down. Bell metal (an alloy of copper and tin, usually mixed in ratio of 3:1) is heated at 1200-1300 degrees and then this molten metal is poured in to the cavity to replace the wax. This process is to be done with great care to ensure that no air bubbles are formed while pouring the metal.
A video by master craftsman Sushil Sakhuja captures the firing process: http://www.youtube.com/watch?v=6qREtAv9hwo
Filing: The filing of the metal surface can take a few hours or a day, depending on the size and design of the product. To give a better finish to the products, many artisans are now also buffing the products.
Note: Dhokra products can be hollow or solid. The above process describes the hollow casting method. Incase of solid casting, instead of a clay mould, wax is used. Hence, during the firing process, a lot more molten metal is used to replaces the wax. The traditional method of casting is the hollow casting using the clay mould.
Caring for the Product
The products turn slightly black over a few years. Apply Brasso to retain the colour and shine.
Problems plaguing artisans
Rising raw material prices is a big challenge being faced by the artisans. High investment in metal and other inputs increases their working capital requirements. Some artisans are experimenting with different materials to bring down costs; such as replacing beeswax with paraffin wax mixed with tar.
Beautiful illustration of how Dokra crafts are made. The pictures make understanding the process even much more easier. As you rightly pointed out, Dhokra is one of the most ancient artforms of India but this art form is now under threat because of rising metal prices which see Dhokra craftsmen now finding it doubly difficult to make ends meet.
ReplyDeleteWe ourselves are involved in a venture where we sell Dhokra items online and these are directly sold by the craftsmen on our site but many a time customers say that they are highly priced due to which they are put off.
We try to convince the customer that if we lower prices then the craftsmen will be at loss. Thankfully most customers who have dealt with have been understanding.
Thanks Kritika :) I believe that the true value of handicrafts lies in its intangibles- its story telling, which adds a world of wealth to its beauty. It helps customers better understand and appreciate handmade products. And since I work with the artisans directly, I have the opportunity to document their beautiful crafts.
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