Once the cartographer has approved the projection, it is transferred from the original cartography to a photographic film master. This original film work is then transferred into a specialized silk-screen image. Each color applied to the sphere requires an individual silk-screen. Depending on the sphere to be created, this process can require 8 to 18 separate hand operations. Each piece is then inspected and passed on to the thermal process.

At this step, each piece must be heat soaked for several hours at high temperatures then fitted into a blowing tool which uses only air pressure to create the hemisphere. To assure optical clarity, the hemispheres are free-blown, similar to glassblowing techniques. Each sphere is therefore slightly different. The hemispheres are then passed to the hands of the trimmer.

At the trimmer, the two hemispheres are trimmed of excess material, then carefully matched to create a complete sphere. Next, the spheres are thoroughly cleaned and polished to remove any residue from the manufacturing process.

Then, the highly skilled globe maker makes a final fitting and bonds the two hemispheres, making a complete sphere. Finally, the globe maker signs and dates a Certificate of Authenticity, personally certifying the quality and appearance of each sphere.