Hand-tooling a mug model vs. 3D-printing and casting itI am creating molds for a 2019 casting-jiggering project to reproduce heavy stoneware mugs manufactured here 50 years ago. I have a profile drawing I want to match (upper left). The solid plaster model on the left was my first attempt at manual tooling. The metal template was time-consuming to ... more I am creating molds for a 2019 casting-jiggering project to reproduce heavy stoneware mugs manufactured here 50 years ago. I have a profile drawing I want to match (upper left). The solid plaster model on the left was my first attempt at manual tooling. The metal template was time-consuming to hand-make, its contour was difficult-to-match to the drawing and the plaster surface turned out rough and difficult-to-smooth. To make the plaster model on the right I printed a shell (using my 3D printer), poured the plaster in, extracted it after set and then smoothed it on the wheel using a metal rib and trimming tool. It matches the drawing perfectly and the round is very true. 3D-printing is revolutionary for this type of thing! The drawings: I hired someone on Upwork.com to make them for me (using Fusion 360). The shell-mold (to cast the model) on the upper right: I printed that too, in two pieces. Context: Casting-Jiggering, 3D-Printing, 2019 Jiggering-Casting Project Friday 6th December 2019 
3D-Printed shell to cast working plaster jigger moldsThe grey outer shell mold on the left was printed in two parts and glued together (at the shoulder). It's vertical split enables me to open it a little. The center model of the outside contour of the mug (on a two-step base) was made by casting the plaster inside another two-piece 3D-printed form I ... more The grey outer shell mold on the left was printed in two parts and glued together (at the shoulder). It's vertical split enables me to open it a little. The center model of the outside contour of the mug (on a two-step base) was made by casting the plaster inside another two-piece 3D-printed form I had made (we had to use a heat-gun and scissors to get the PLA printed form off of that plaster). It smooth the surface on the wheel using a metal rib and trimming tool. Then I stretched a rubber band around the first step at the bottom (because the shell was a little lose-fitting). Now the outer shell mold fits perfectly and clamps tightly in place. To cast a jigger mold it is just a matter of soaping the plaster model and the inside of the shell and pouring in a mix of 1300 pottery plaster and 900 water. Context: 3D-Printing, Jiggering, Casting-Jiggering, 2019 Jiggering-Casting Project Friday 6th December 2019 
The incredible utility of 3D printing master handle moldsThese molds are 3D-printed from PLA filament. They are part of my 2019 year-long casting-jiggering project. A quick soaping, 164g water, 236g plaster and a fifteen minute set produced this plaster mold. It takes time to learn how to soap the masters properly to get optimum quality, but these molds ... more These molds are 3D-printed from PLA filament. They are part of my 2019 year-long casting-jiggering project. A quick soaping, 164g water, 236g plaster and a fifteen minute set produced this plaster mold. It takes time to learn how to soap the masters properly to get optimum quality, but these molds seem to work well regardless. The two halves mate with a tiny amount of play, but it is easy to line them up perfectly (the play actually enables lateral movement that aids in releasing the handle). It is actually easier to cast handles solid rather than pour the slip out, they can be ready to apply in an hour after pouring. The ease of making these molds puts slip casting within much easier reach for potters and small companies. Context: Final cast-jiggered mug beside original 3D-printed mock-up, 3D-Printed master mold, handle mold made in it, first cast, Slip Casting, 3D-Printing, 2019 Jiggering-Casting Project Thursday 5th December 2019 
Fusion 360, my choice for 3D modellingIntimidation by the complexity of this type of software is the biggest obstacle you will face to learning 3D design (for 3D-printing). That being said, the new mission of AutoDesk, the leader in CAD software for 30 years, is to make it easy and universal! Fusion 360 has a lot of advantages. It is a ... more Intimidation by the complexity of this type of software is the biggest obstacle you will face to learning 3D design (for 3D-printing). That being said, the new mission of AutoDesk, the leader in CAD software for 30 years, is to make it easy and universal! Fusion 360 has a lot of advantages. It is a standard. There is a simple learning curve via Tinkercad.com, videos on Youtube, easy online help and many freelancers to hire (at Upwork.com). It is free to qualifying users (teachers, students or people who earn less that $100k/yr), the fact that software of this kind of power and utility is actually available to anyone that wants to try it is amazing. Fusion 360 (and other 3D design products) cannot run 3D printers (3D slicers do that). Fusion 360 is very demanding on the processor and graphics hardware of your computer, typical laptops are not powerful enough. Context: G-Code 3D Printer instructions, Fusion 360 on YouTube , 3D-Printing, 3D Designer, 2019 Jiggering-Casting Project Thursday 5th December 2019 
Laguna B-Mix on Steroids: Wedge in some Plainsman Fire-Red!Both pieces have a transparent glaze, G1947U. The Fire-Red (a blend of Plainsman A1/M2 and St. Rose Red) was mixed as a slurry, dewatered to plastic form and then wedged in to the B-Mix (left piece has 10%, the other 20%, the bar in front shows the pure material). The A1 supplies most of the ... more Both pieces have a transparent glaze, G1947U. The Fire-Red (a blend of Plainsman A1/M2 and St. Rose Red) was mixed as a slurry, dewatered to plastic form and then wedged in to the B-Mix (left piece has 10%, the other 20%, the bar in front shows the pure material). The A1 supplies most of the speckle, the St Rose and M2 impart the color. This addition does not affect the working properties of BMix (it still throws very well). An added benefit is that pieces dry better. Fired strength and maturity are minimally affected (porosity stays around 1%). With a 20% addition the surface of the unglazed clay is almost metallic. Silky matte glazes, like g2571a, are stunning on a body like this.
Context: Laguna B-Mix Cone 10R mugs with Alberta and Ravenscrag glazes, Laguna B-Mix, B-Mix+Fireclay with Ravenscrag GR10-A, GR10-C glazes, Reduction Speckle, Reduction Firing Thursday 5th December 2019 
Polish the plaster surface, not the 3D-printed shell-moldThis plaster model was just removed from the 3D-printed shell behind. It dropped out easily (after tapping it at-an-angle on the corners), this worked well despite the resolution lines on the surface. While I could have spent time sanding and smoothing the inside of the shell-mold, it is actually ... more This plaster model was just removed from the 3D-printed shell behind. It dropped out easily (after tapping it at-an-angle on the corners), this worked well despite the resolution lines on the surface. While I could have spent time sanding and smoothing the inside of the shell-mold, it is actually far easier to smooth the surface of the plaster form after extraction. Seconds with a metal rib completely smooths any of the surfaces. And remember, it is easier to remove plaster items cast inside of 3D-printed molds rather than cast around the outside of them. Context: 3D-Printing Thursday 5th December 2019 
A 3D-printed spout greatly increases the utility of this casting moldIt was glued down using the casting slip itself (it stuck in seconds). About ten minutes after draining a fettling knife was run around the inside, then it detached easily. The overhung lip produced imparts structural strength, for drying and firing, to the thin walled piece. This spout has ... more It was glued down using the casting slip itself (it stuck in seconds). About ten minutes after draining a fettling knife was run around the inside, then it detached easily. The overhung lip produced imparts structural strength, for drying and firing, to the thin walled piece. This spout has advantages over the traditional "spare" built in to the upper part of a mold. It enables a one-piece mold. The lip can be more overhung. Draining is cleaner and easier. Molds are lighter. Extraction can be done sooner and it is easier. The spout does not absorb so there is less scrap. The degree of overhang is adjustable by simply printing new spouts. Context: 3D-Printing, Slip Casting Sunday 1st December 2019 
Cooling rate drastically affects the appearance of this glazeThis is G2934Y satin matte with Mason 6600 black stain. The piece on the left was fired using a slow-cool firing schedule (C6DHSC). The schedule for the one on the right turned the kiln off at 2100F (after a half hour drop-from-2200F-and-hold), then it free-fell. The slow cool gives the glaze on the ... more This is G2934Y satin matte with Mason 6600 black stain. The piece on the left was fired using a slow-cool firing schedule (C6DHSC). The schedule for the one on the right turned the kiln off at 2100F (after a half hour drop-from-2200F-and-hold), then it free-fell. The slow cool gives the glaze on the left time to crystallize, thus it is no longer a satin matte. It is interesting that to this mix of the glaze I added 20% glossy clear, yet it still matted on the slow cool. Context: G2934Y - Cone 6 Magnesia Matte Low LOI Version, Matte Glaze Tuesday 26th November 2019 
Why does transparently glazed terra cotta look better at cone 03 than 04?Terra cotta bodies typically develop richer color at cone 03 and fire much stronger. Glazes melt better and thus micro-bubbles pass through easier, this produces better transparency and a more brilliant surface. Notice that crazing is beginning on the one of the left. But because of better ... more Terra cotta bodies typically develop richer color at cone 03 and fire much stronger. Glazes melt better and thus micro-bubbles pass through easier, this produces better transparency and a more brilliant surface. Notice that crazing is beginning on the one of the left. But because of better body:glaze interface and development of better vitrification the one on the right is not crazing. Cone 03 is somewhat of a sweet-spot for this specific body, firing higher begins decomposition processes that generate gases that disrupt the surface. Needless to say, accurate firing is needed to fire at cone 03 with ongoing success. Context: Terra cotta, Vitrification Sunday 24th November 2019 
White stain. Does it work?This is G2934Y matte glaze base with opacifiers added. It has been applied to a dark-burning body to demonstrate the comparative degrees of opacity. The stain is Mason 6700 white. While it does not opacify nearly as well as tin or zircon, it does produce a smoother surface. Context: Opacifier, Opacification, Stain Sunday 24th November 2019 | Contact Us:
Use the contact pages within or outside your account at Insight-Live.com
Login to your online account
Chemistry plus physics. The on-line successor to desktop Insight. Get an account for as little as $15. It does so much more.
Maintain your recipes, test results, firing schedules, pictures, materials, projects, etc. Organizing that data will better empower you to adjust, formulate and fix your recipes and processes. Link, share and publish.
Because it is on-line you can access your data from any connected device. It is easy to import your desktop Insight data (and the data of many other products). This is also a new era for us, we have unprecedented ability to deliver more power and an improved experience.
Teaching ceramics? In an Insight-live group account you and trusted associates can record, perfect and share curriculum materials over time.
Still using desktop Insight? Convert to the new system. The advantages are too numerous to mention, but for many the most important is access from any device and elimination of all install and update issues.
Group accounts for industry and education. Private accounts for potters. This is the future!
Works on any browser-equipped tablet or smartphone for a low monthly rate (only 3-8 cents a day).
Get started.
Still available for Mac, PC, Linux
Interactive glaze chemistry calculations (legacy, no longer supported)
Teaching ceramics? Use this as the least-hassle way to teach glaze chemistry. It is free and unrestricted.
Students can later upgrade to our state-of-the-art Insight-live.com online system. You can download this here or in the Files panel within your Insight-live.com account.
What people have said about digitalfire
• I found your site and spent a long time studying various parts of it. I intend to use it alot, and hence I probably purchase the software in due course.
• Ceramicmaterials.info is a fantastic resource!
• Your web is great!
• Firstly, I want to thank you about this very good site in the net which helps very much in the development of the ceramics industry.
• Again, thanks for being such a resource to potters over the years!
• I love the site. I use it all the time at the Clay Business, and I feel like I have not even touched the surface.
• Thanks for the wonderful service.
Click here to see all 191
What people have said about Insight-Live
• WOW, WOW, WHAT GREAT INFO! thankyou! I am going to pass your site on to someone i know who is more keen on the science of glazes, than the potting, unlike me... she will love your test works and pics Wow! Thanks again.
• Planarity in 1200c tile May 2018
• Thank you again for the amazing website and wealth of information!!! InsightLive is proving to be an incredible asset as well!!!
• Your site is a fantastic resource, I recommend it to everyone.
• I personally think that collaborations with the greatest expert in the sector makes me richer in knowledge and it will allow me to discover the fantastic secrets of ceramic.
• Love the post (about leaching in glazes). I am the bad guy on Facebook ceramic because I always bring up this subject. So sad.
• Thank you so much for the fantastic info and knowledge you provide for us potters on your page!
Click here to see all 124
|
