About the Doll Molds
There are two types of molds used to create Sadowara dolls: clay molds and plaster molds.
Clay Molds
Masuya currently preserves nearly 200 clay molds, including some that have been passed down since the workshop was first established. These molds are used in the traditional hand-pressing method.
Because clay molds gradually lose their ability to absorb moisture when used continuously, they must be thoroughly dried after each use. As a result, large quantities cannot be produced at once. However, with proper care, clay molds experience very little wear and can be used for generations.
Plaster Molds
During the Showa era (1926–1989), plaster molds became increasingly common. They were primarily used for slip-casting, although some of the dolls produced at Masuya today are still hand-pressed using plaster molds.
Plaster absorbs moisture quickly, making it suitable for large-scale production. However, unlike clay molds, it wears down relatively easily over time.
How Sadowara Dolls Are Made
There are two traditional methods used to create Sadowara dolls: hand-pressing and slip-casting.
Hand-Pressing
Hand-pressing is the traditional method of Sadowara doll making. Thin sheets of clay are carefully pressed into molds by hand to form the shape of the doll.
The process typically uses a two-part mold consisting of front and back sections. After the clay is pressed into the mold, it is left to rest for a short time. As the clay begins to dry, it shrinks slightly and separates from the mold, making it easier to remove. The front and back pieces are then joined together, and any excess clay along the seam, known as burrs or flash, is carefully trimmed and smoothed by hand.
This technique has been used in Sadowara doll making for generations and remains one of its most important traditional methods.
Slip-Casting
In the slip-casting method, clay is mixed with water and sodium silicate to create a liquid clay mixture known as slip.
A two-part plaster mold is tightly secured with rubber bands or other fasteners to prevent leakage, and the liquid clay is poured inside. After a period of time, the moisture is absorbed by the plaster, causing the clay to solidify along the inner surface of the mold. The remaining liquid clay is then poured out, leaving a hollow form with an even wall thickness.
Because multiple dolls can be produced relatively quickly using the same mold, slip-casting became widely adopted from the mid-Showa period (around the 1950s–1970s) onward.
Most Sadowara doll molds consist of two matching halves—front and back—which are joined together after forming.
Depending on the type of doll, however, some molds are made from only a single side. Certain figures also feature separately attached hands or heads, requiring dedicated molds for these individual parts.
These techniques, known as sashi-te (inserted hands) and sashi-kubi (inserted heads), have long been used in traditional Japanese doll making, including Kabuki dolls and historical Hina dolls. They are one of the distinctive sculptural characteristics that contribute to the unique appearance of Sadowara dolls.
