Our Process

Depending on the complexity of the piece, the design can take minutes or several hours. The project is imported into a computer, edited and sized until it is ready for cutting. We use a CNC plasma cutting system. Plasma is a combination of oxygen and electricity, which produces a spark that burns away the material.

Once the piece is cut it must be cleaned. This requires grinding both the back and front (dross removal) of the piece. We use two kinds of steel. Hot rolled steel is typically used with the thicker pieces and must be cleaned first by soaking in muriatic acid and water. This removes the mill scale. It is then rinsed with water and dried with compressed ai, then ground front and back. Using cold rolled steel eliminates the acid cleaning but is more expensive. 

After grinding, many of our pieces have more decorative grinding to make them appear dimensional and unique. We continue to explore various color options including heat coloring using a torch, and hand staining, as well as other patina finishes to make our work one-of-a-kind. Most of our work has a powder coat finish that can be a color or clear coat over the heat colored pieces, that makes our product durable for outside.

Gerald Stoner, of Underhill Ironworks teaches sculpture, photography, and visual arts at Bellows Free Academy in St. Albans Vermont. In addition Gerald is an Instructor at Community College of Vermont in St. Albans and Burlington teaching ceramics, sculpture, and photography one and two respectively. Gerald's sculpture and photography has been displayed throughout New England and group exhibitions in Colorado, Illinois, New York and Texas. Gerald has received various awards for his work at a number of shows including Noble horizons in Salisbury, Connecticut, Open Spectrum in Libertyville, Illinois, and the Annual National Drawing and Small Sculpture Show in Corpus Chirsti, Texas. Gerald was born in Kokomo, Indiana, and grew up in upstate New York. He received his B.A in sculpture and photography from State University of New York at Plattsburgh and his M.F.A in sculpture from Northern Illinois University. He lives in Underhill, Vermont with his wife and two young sons.

“The process of working with steel is natural for me, descending from many generations who worked in the steel mills of the Midwest. The dexterity of steel remains a constant exploration in my work, celebrating the material. The permanence and the ability of steel to be whimsical, brutal, and atmospheric are embraced in my sculpture. The sculptures are constructed from steel yard finds that are firstly composed with sketches and evolve intuitively in the studio. All sculptures are to be exhibited on their own, but I have found that displaying them as a group creates an atmosphere of personalities.”

Geraldkstoner.com

Located in Poultney, Vermont, Jen Herzer creates sculptures from rock, transforming natural river stone into visually stunning works of art.

With a background in biology and environmental science, Jen's earth-friendly spirit led her to explore Vermont's local streams and rivers where she gathered rocks of varying sizes, shape and color.

Every piece she creates is as unique and mysterious as the rocks they are formed with, and capture the exquisite, wild beauty of Vermont in their impressive form.

JoAnn Flanagan of Hunger Mountain Hardwoods is a sculpture artist based out of Middlesex, VT. 

"My husband Jim and I have lived off grid since 1989 on property that is in forest management. This gives me access to a vast amount of organic materials to make rustic and country home accessories. We are constantly working in the woods, collecting firewood, maintaining a sugarbush and wild Christmas tree areas. When a tree is taken, all of it is used; some of it for fire wood, some goes to our saw mill, and the brush is left for habitat. Interesting wood, crotch wood and burls go to local wood workers for bowls and furniture. I get the bark, fungi, and interesting twisted limbs for my work. Chaga from Birch trees is saved for tea."

“Blacksmithing can transform iron from its raw state into a beautiful work - a very gratifying experience. I am inspired by organic forms that are found in the natural world. Art gives meaning to our lives, and while I enjoy producing traditional forms of ironwork, my greatest reward comes from creating my own abstract and functional designs.” - Michael Harrigan

Michael earned a B.A. in sociology from Merrimack College, and then attended The Modern Welding School in New York. Intrigued by the transformation of metal by fire, he took a blacksmithing course which sparked an enduring interest in creative and decorative metalwork. Michael eventually set up a small forge in Vermont where he makes traditional ironwork and experiments with creating new designs. His recent work is organic in feeling and combines a fluid and lyrical line with the vigor and strength of iron.

Artist Aaron Stein grew up in the Hudson River Valley of New York State during the 60s and 70s.  The son of two accomplished artists, he was drawn to his father’s passion for railroads and anything rusted.   However, in stead of railroads, automobiles are Aaron’s passion; particularly if they are wrecked.

Stein earned a BFA in Industrial Design and a Bachelors in Landscape Architecture allowing him to explore his interests in art, sculpture, and design.  In 1998 Stein created Revival Studio, his multidisciplinary art and design studio that is located in the heart of Burlington, Vermont’s thriving South End Art District.  Stein says “It’s my personal junkyard where I have my materials and tools in overflowing piles of inspiration all covered with a protective covering of dust”.

“I live in the beautiful Champlain Valley of northern Vermont, an area blessed with access to beautiful mountains, streams and backwater ponds. These areas provide much inspiration for my nature pieces. Canoeing these backwaters bring me into intimate contact with dragonflies, lily pads, cattails, autumn leaves etc. I enjoy recreating these scenes in sculpture. I utilize copper extensively in my work. I do not attempt to doggedly reproduce what I see but rather use my observations for inspiration. Other pieces are inspired by everyday Vermont scenes and others... simply from wanderings of my imagination.” - John Arthur

Operating out of their workshop in Essex VT, Father and daughter duo Alissa and Jason Kenwood create sculptural pieces out of screws, bolts, and whatever repurposed metals they can find. By using salvaged and scrapped metals whenever possible, they are able to breathe new life into objects that would otherwise be thrown out.