How Hakata Dolls Are Made

The process of creating Hakata Dolls varies among masters and families, who have been the recipients of techniques and traditions that span centuries. However, these are the basic steps shared by all Hakata Doll makers.

First, Hakata Doll makers procure their own clay, or tsuchi locally. Our featured artist Koshou Sato digs for clay in a mountain behind his house in Fukuoka City. His clay is called Hakata Nana Kuma Tsuchi, after the area where the clay is found.

The clay is then taken through a complex refining process which includes drying, crushing, elutriation (where lighter particles are separated from heavier ones), a second drying, aging, and kneading.

Hakata Doll makers often sketch out the doll they wish to create until it suits their vision. The clay is then carefully kneaded, and a rough figure is sculpted in the desired pose. This sculpture is further refined, adding details and textures. A perfect prototype is created, and this is the doll from which a mould can be created. (Some dolls, however, are created as individual works).

Next, a plaster mould of the doll is formed. Plaster mould technology has been used to create Hakata Dolls since the late 1800s. Previous to this, Hakata Doll makers employed bisque-fired pottery press moulds.

After the plaster mould has been fashioned, kneaded clay is pressed into the mould to create a new doll.

This doll is then fired, usually at a temperature of 900°C to 1000°C. Wood kilns were used until the mid 1900s, when electric and gas kilns began to gain favor.

The unglazed doll is then painted. Some artists have secret firing methods that give the clay a perfect flesh tone. However, the faces of dolls are often painted white with gofun, a pigment derived from oyster shells. Hundreds of layers of gofun may be applied to the doll in order to create a perfect white tone.

The artist then paints the kimono, obi (belt), and kimono patterns onto the doll. As you can see in Koshou Sato's work, gold powder can be applied in order to create stunning imagery.

The final step for many doll makers is the painting of the doll's face. Masterful work can bring life into the eyes and the doll itself.

Source: Japan Arts, which presents work by our feature artist, Koshou Sato