The F.U.S.E. Story
Catherine Lottes

Since early 1997, the F.U.S.E. Design Group in Milwaukee, Wisconsin has been developing unique products from recovered waste glass for use in the architecture and design industries. The idea of working with glass has been in my mind since I worked as a stained glass cutter at an exclusive Tiffany reproduction studio ten years ago. My research brought me into contact with Bob Kirby, an engineer who had worked with the Clean Washington Center in Seattle to gather data on technical applications of recycled glass. My initial meeting with Kirby went well. Though still in its infancy, the process he had been devising looked incredibly promising. Composed entirely of 100 percent postconsumer and/or postindustrial glass, it was completely benign (no free silica in the glass so it will not aggravate respiratory conditions or cause silicosis). The finished product is stronger than ceramics, yet requires less energy to produce. Polymers or synthetic additives are not used so there are no VOC chemicals to off gas. At the end of its life cycle, the glass can be reground and recycled again.

But making a business by using this technology had many obstacles. Then Kirby e-mailed me: “I tried something new in the kiln last night and it looks very cool.” He sent me the sample, which resembled frozen water droplets. It was absolutely stunning, and everyone who saw the glass instantly loved it.

I had a design idea for a computer desk in the works, and this new glass was perfect. We managed to make a prototype of the desk featuring the unusual panels, and the prototype debuted at the 1997 International Contemporary Furniture Fair in New York City.

There was an overwhelming response for both the glass and the desks. Even more enthusiasm was expressed when we revealed that everything in our booth was made entirely from recycled content materials. It appeared that we were onto something very good. We received a flood of requests from designers and architects alike to make a variety of architectural and design related items with the glass. Unfortunately, I had to tell them that I was still in the process of doing my feasibility study so I was not in a position to produce any products yet. Many hardships followed as I did my best to self-finance my endeavors.

Fortunately, I had already picked up some loyal clients: Fire & Water Lighting, owned by New York architect David Bergman; Joe Locher, of Yes Men Corp. in Milwaukee; Walker Group/CNI, an international architectural firm in the process of renovating a textile building in Greenwich Village, New York; and an Arena & Company project for Soto Restaurant in old Philadelphia.

In July of 1999, I relocated to an ideal 7,000 square foot industry facility on the east side of Milwaukee. Since then I have also picked up several more clients (in conjunction with new problems to solve).

Although my commitment to sustainability is unwavering, my attitude toward the recycled content aspect of my work has been “tempered” somewhat over time. Sourcing good quality glass from the waste stream has been extremely challenging, as sources are often fickle. I have several clients to whom it is very important that the products I provide for them are authentically “green”.

However, I have found that I would not even have to indicate the origins of the glass to the rest of my clients. They love the glass for the beauty that is inherently part of it.

Catherine Lottes can be contacted at F.U.S.E. Design in Milwaukee — (414) 332-6615.