As we know glass can be dangerous, smashed shards are sharp and can cut deep into the skin. When smashing a bottle or a window all ways wear protection of some kind or be prepared to end up with some nasty cuts. This is where tempered glass and sugar glass come in handy and become less dangerous. There’s a scene in Django Unchained where Leonardo Dicaprio slams his hand on actual glass and cuts his hand and continues with the scene. Much of a shock the team was so amazed they kept it for the duration of the film and changed his costume to have a rag over his hand for other scenes. Now if the production crew knew he was going to accidentally cut his hand they could of prepared for the with a sugar glass cup and its be a lot safer to break. The scene was amazing either way adding to Dicaprio’s character. It was just an example to show how glass can actually harm you when you break it unsafely. Tempered glass is different from sugar glass. Tempered glass is meant to break a second before the actor breaks it with tiny explosives to break the glass. Tempered glass would fall under the pyrotechnics part of the production team.

Now here’s a way to make sugar glass, (surprise it involves sugar), you melt sugar at 320 degrees, then once melted, you pour the melted sugar into your mold or pan. BE EXTREMELY CAREFUL. Once poured, let it settle, or if you’re pouring in a 3D mold, rotate the sugar evenly to coat the sides and pour the excess out to get a bottle shape. Once ready take the glass out of the pan or mold and it’s ready for use. Here’s a key note: keep the sugar glass in a cold environment before use, as heat tends to melt sugar.

If you need a visual example here’s two links for your use.