In a market flooded with fragile, poorly designed smoking accessories, one company has been quietly revolutionizing the industry through engineering excellence rather than flashy marketing. Thick Ass Glass (TAG) has built a loyal following among enthusiasts who value durability, functionality, and precision over fleeting trends. Founded on the principle that smoking accessories should be built to last and perform consistently, TAG has carved out a unique space in the industry. I recently sat down with Brian Handschuh, the founder and driving force behind Thick Ass Glass, to discuss the science of percolation, the manufacturing process, and why investing in quality makes all the difference in the world.
Zach: Brian, thanks for making time for this conversation. Let’s start with your background. What led you to focus so heavily on the engineering aspects of glass?
Brian: I’ve always been drawn to the technical side of things. Before TAG, I saw this disconnect in the industry where people were either buying cheap, thin glass that broke easily or overpaying for artistic pieces that looked nice but didn’t necessarily function well. I wanted to bridge that gap by creating products that were both durable and scientifically engineered for optimal performance.
When I say engineered, I mean it literally. We use CAD designs to calculate airflow, test different percolation systems, and find the balance between diffusion and drag. It’s not just about making glass thicker—though that’s certainly part of it—it’s about understanding the physics of how smoke moves through water and designing around those principles.
Zach: Speaking of percolation, can you break down how different percolator designs affect the smoking experience? It seems like there’s a lot of misinformation out there.
Brian: There absolutely is. A lot of companies add percs because they look cool, not because they’ve tested how they actually function. Percolation is about breaking smoke into smaller bubbles to increase surface area contact with water, which cools and filters the smoke more effectively.
Take tree percs versus honeycomb percs, for example. Tree percs create larger bubbles through fewer pathways, which means less resistance but also less diffusion. Honeycomb percs create thousands of micro-bubbles through multiple small holes, which maximizes filtration but can create more drag if not designed correctly.
The key is finding the sweet spot for each design. Our super slit puck percs, for instance, have a higher slit density than competitors’. This is more difficult and time-consuming to produce, but it creates optimal bubble size without restricting airflow. We could save on production costs by using fewer slits, but function would suffer.
That’s the difference between engineering and just manufacturing—we make decisions based on performance, not just ease of production.
Zach: Let’s talk about the manufacturing process. How are TAG bongs actually made, and how does that differ from mass-produced pieces?
Brian: Great question. Most glass work follows a four-step process, but the devil’s in the details. We start with premium borosilicate glass, which contains boron trioxide that gives it a lower coefficient of thermal expansion. This means it doesn’t crack easily when exposed to temperature changes.
For a typical beaker bong, we begin with a pre-made glass tube on a lathe. The tube is flared on one end, and then glass is gathered to enclose the beaker bottom base. This part is critical—the glass must be kept turning to maintain symmetry, and we make ours significantly thicker at the base (12-16mm versus competitors’ 3-6mm).
Next, we create the neck by heating and turning the section above the water chamber until it’s uniform and proportional to the base. Then we craft the mouthpiece, focusing on ergonomics with no sharp edges.
Finally, we create the removable pieces—the downstem and bowl. This is where many manufacturers cut corners, but we use custom super-thick joints, especially on our heavy wall beakers. We could save weight and production costs with thinner joints, but that would create weak points.
What sets us apart is our quality control and attention to detail throughout this process. We maintain strict glass thicknesses in welds, tight tolerances on diffusers, and adhere to our design specifications even when it makes production more challenging. Many producers prioritize the cheapest production method over design integrity—we don’t.
Zach: Reddit users often mention how even their TAG pieces that have been dropped survived when other brands would have shattered. Is the durability really that different?
Brian: It absolutely is. I’ve seen posts from customers whose TAG pieces have fallen from coffee tables onto hardwood floors and survived without a crack. That’s not accidental—it’s by design.
The thickness difference is substantial. When a 3mm base hits a hard surface, there’s very little material to absorb and distribute the impact energy. With our 12-16mm bases, that same energy gets dispersed throughout a much larger mass of glass.
But it’s not just the base thickness. We reinforce stress points and joints, which are typically the first places a bong will break. Our joint welds are thicker, our connections are reinforced, and we pay attention to weight distribution to create more stable pieces.
I always tell people: if you’re spending good money on a piece, wouldn’t you rather get something that lasts years instead of months? It’s actually more economical in the long run.
Zach: Let’s discuss recyclers, which seem to be gaining popularity. What makes a well-designed recycler, and why might someone choose that over a traditional beaker?
Brian: Recyclers represent one of the bigger innovations in glass design over the past decade. The principle is brilliant—they continuously cycle water between chambers, ensuring fresh water hits each smoke bubble while preventing stale smoke build-up.
A properly designed recycler needs precise balance. The drain must be sized correctly relative to the uptake tube, the water level needs to be just right, and the airflow paths must be engineered for consistency. When done right, you get incredibly smooth hits with virtually no splashback.
Recyclers are particularly popular for concentrate users because they preserve flavor while providing excellent filtration. The continuous cycling keeps the vapor fresh and prevents it from becoming stale in the chamber.
The trade-off versus a traditional beaker is complexity. Recyclers have more intricate glasswork, which means more cleaning and maintenance. For everyday flower smokers, a solid beaker might be more practical, while flavor chasers and concentrate enthusiasts often prefer the refined experience of a well-designed recycler.
At TAG, our recyclers go through extensive testing to ensure they actually function as intended—not just look cool. The internal drain holes, return paths, and percolation systems are all calibrated to work together as a system.
Zach: You mentioned concentrates. How does designing glass for concentrates differ from designing for dry herb?
Brian: It’s a completely different approach. With dry herb, you’re combusting material, which creates hotter, more voluminous smoke. You typically want more water volume and percolation to cool and filter that smoke.
With concentrates, you’re vaporizing rather than combusting, and the goal is to preserve delicate flavors while providing just enough diffusion to cool the vapor without over-filtering it. Concentrate rigs tend to be smaller with less percolation to maintain flavor integrity.
The airflow dynamics are different too. Dab rigs benefit from more direct paths with less restriction, while flower pieces often use more complex percolation. The joint types also differ—dab rigs traditionally use male joints for female bangers, though this has evolved over time.
Temperature retention is another crucial factor for concentrates. You want materials and designs that maintain consistent heat at the nail or banger, which influences how we engineer those pieces.
At TAG, we design dab rigs specifically for concentrate use rather than just scaling down our bong designs. The dimensions, water volumes, and percolation systems are all optimized for vapor rather than smoke.
Zach: Let’s talk about your Made To Order service. How does that work, and why did you decide to offer customization options?
Brian: We launched our Made To Order (MTO) service in early 2021 because customers kept asking about specific variants or color options that weren’t currently in stock. Traditionally, production glass brands can’t offer custom orders because they need high production quantities of specific variants to be cost-effective.
The MTO service allows customers to request virtually any variant from any item listed on our website. Want a specific color combination that’s not in stock? Need a particular logo or feature on an existing design? We can do that.
It works pretty simply: customers tell us exactly what they want, we provide a quote, and once approved, we make it happen. It takes a bit longer than our regular production pieces, but you get exactly what you want.
This approach has been a game-changer because it gives customers the customization normally only available from individual glass artists, but with the engineering precision and quality control of our production process. It’s the best of both worlds.
Zach: What are some of the biggest misconceptions people have about glass quality or functionality?
Brian: One of the biggest misconceptions is that more percolators automatically mean better filtration. I see people gravitating toward pieces with four or five different percs thinking they’re getting superior function, when in reality, they’re often getting restricted airflow and diminishing returns on actual cooling.
Another is conflating price with quality. Some brands charge premium prices based solely on name recognition, not superior engineering. Conversely, people often assume all affordable glass is low quality, which isn’t necessarily true if you know what to look for.
People also tend to underestimate the importance of joint quality. They focus on the showier aspects like percs or colors, but the joint connection is one of the most critical components for both function and durability. A poorly made joint creates air leaks and stress fractures over time.
There’s also confusion about diffusion versus drag. Optimal percolation isn’t about creating the most bubbles possible—it’s about creating the right size and distribution of bubbles while maintaining appropriate airflow. Too much restriction makes for a frustrating experience, no matter how cool it looks.
Zach: How do you test your designs before bringing them to market?
Brian: We have a multi-stage testing process. First, we start with CAD designs and mathematical modeling of airflow dynamics. This gives us a theoretical foundation for how a piece should function.
From there, we create prototypes and conduct extensive real-world testing. We measure water displacement, bubble formation, draw resistance, and cooling efficiency. We’re literally testing things like the temperature differential of smoke from bowl to mouthpiece to quantify cooling performance.
We also do durability testing—controlled drops and stress tests to identify potential weak points. When we find issues, we go back to the design phase and make adjustments.
This iterative process is why our products often have seemingly small but important differences from competitors—like the angle of a downstem, the number of slits in a diffuser, or the thickness of a joint connection. These details might seem minor, but they make a significant difference in daily use.
Perhaps most importantly, we get real user feedback. Our team actually uses these products, and we have a network of testers with different preferences and smoking styles. Something might look great on paper but feel awkward in hand, so that human element is crucial.
Zach: Let’s talk about glass thickness and materials. Beyond just making things “thick,” are there specific design principles you follow?
Brian: Absolutely. “Thick” is part of our name, but it’s really about strategic reinforcement, not just making everything bulky. We focus on stress points and high-impact areas like bases, joints, and connection points.
For example, our beakers have bases up to 16mm thick, but the walls might be 7-9mm. This creates the right balance of durability without unnecessary weight. The neck needs to be thick enough to resist breakage but not so thick that it becomes unwieldy.
Material quality is equally important. We use high-grade borosilicate glass with the right composition for heat resistance and structural integrity. Not all borosilicate is created equal—the exact formulation affects everything from workability during production to long-term durability.
We also pay attention to annealing—the process of cooling glass under controlled conditions to reduce internal stress. Properly annealed glass is significantly more resilient to thermal shock and physical impact. Many mass producers rush this process, which creates microscopic stress points that lead to breakage later.
Our philosophy is simple: identify where pieces typically fail and reinforce those areas without compromising function or dramatically increasing cost. It’s targeted engineering, not just making everything thicker.
Zach: What advice would you give to someone looking to make their first quality glass purchase?
Brian: First, figure out your smoking style and priorities. Are you a daily user who needs something easy to clean? Do you prefer huge, filtered hits or quick, flavorful ones? Are you primarily at home or on the go?
For most first-time buyers, I recommend a medium-sized beaker (12-16 inches) with a diffused downstem. It’s the most versatile platform—stable, easy to clean, good filtration, and compatible with upgrades like ash catchers if you want to add them later. The 14mm joint size is standard and gives you the most accessory options.
Focus on joint quality and glass thickness at stress points. Look at the base thickness and how the downstem connects to the main chamber—these are the areas that determine longevity.
Don’t get distracted by flashy percs or complex designs for your first piece. Master the basics, understand what you enjoy, then expand your collection based on that knowledge.
And finally, buy from companies that stand behind their products. Look at their customer service reputation, warranty options, and how they handle issues. The cheapest option is rarely the best value in the long run.
Zach: Where do you see the future of glass design heading?
Brian: I see three major trends emerging. First, there’s growing interest in modular systems that let users customize their experience. People want the flexibility to switch between different percolation styles or adapt their piece for different materials.
Second, I think we’ll see more scientific optimization of percolation systems. As the market matures, consumers are becoming more educated about function over flash, and they’re demanding pieces that deliver measurable performance improvements.
Finally, there’s increasing interest in specialized pieces designed for specific consumption methods rather than one-size-fits-all approaches. The needs of a concentrate user are different from someone who primarily smokes flower, and the industry is responding with more purpose-built designs.
At TAG, we’re focused on all three areas—enhancing modularity, refining percolation science, and developing specialized pieces that excel at specific functions. We’re constantly testing new designs and refining existing ones based on user feedback and internal testing.
The companies that will thrive are those that understand smoking isn’t just about getting high—it’s about the complete experience, from the feel of the piece in your hand to the smoothness of each hit to how easy it is to clean and maintain.
Zach: To wrap up, what makes you most proud about what TAG has accomplished?
Brian: What makes me most proud is seeing how we’ve changed the conversation around quality in this industry. When we started, thick glass was relatively niche. Now, durability and engineering are part of every serious discussion about quality.
I’m also proud of our customer base. TAG users tend to be knowledgeable, passionate, and willing to invest in quality over hype. The Reddit comments you mentioned earlier mean a lot to me—seeing people genuinely excited about their experience with our products and sharing that with others.
But mostly, I’m proud that we’ve stuck to our principles. We could have cut corners to increase margins or chased trends at the expense of function, but we’ve stayed focused on making the best possible products at fair prices. In an industry where marketing often overshadows substance, I think that commitment to quality stands out.
Zach: Brian, this has been incredibly informative. Thanks for giving us this behind-the-scenes look at what makes TAG different.Brian: Thanks for the thoughtful questions, Zach. I could talk about this stuff all day—it’s a passion, not just a business.
Zach Pintaro serves as Editor-in-Chief of Copetti News, where he leads the digital-first publication’s mission to deliver innovative, impactful journalism for the modern era.
