587 - Glass Design Meets Actual Production with Andrés Hernandez of Fusion Glass and Chad Micheal of Chad Michael Studio
How many times have you reached for a bottle on the shelf simply because the glass looked incredible or the label caught your eye? At Pursuit Spirits, we talk endlessly about what goes inside the barrel, but the multi-million dollar engineering and design process that gets that liquid onto the shelf is an entire science of its own. Today, we’re sitting down with Andrés Hernandez of Fusion Glass Mexico and Chad Michael of Chad Michael Studio to break down how custom bottles are engineered, designed, and brought to market. Andrés takes us behind the factory curtain to explain the mechanics of glassmaking—from collecting, washing, and remaking 100% PCR (post-consumer recycled) glass to managing extreme temperatures, color formulation, and structural tolerances. Then, Chad breaks down the creative process of turning a brand story into a physical icon, starting with a concise client questionnaire and translating brand DNA into custom glass, label textures, and closures. Whether you’re navigating minimum order quantities, weighing stock glass versus bespoke molds, or testing glass for impact resistance and machine line compatibility, this episode is a deep dive into the silent, high-stakes partner of every great whiskey: the package itself.