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Making ceramic tile shapes by 3D printing your own cookie cutters

This was done on an affordable RepRap printer. The red plastic templates were drawn in Illustrator, extruded in Fusion 360 and sliced and printed using Simplify3D (which took about 30 minutes each). The round wooden block was used to press these cookie-cutters into the clay. The plastic wrap made sticking a non issue (and rounds the corners nicely). The clay is a low fire, buff burning talc body (Plainsman L212). Commercial bottled glazes were applied by brushing (in three coats) after bisque. The tiles were fired at cone 03. This is an old classic design that I discovered when researching Damascus tile. The toughest obstacle was learning how to use Fusion 360. It turns out that cookie cutters are a starter project for many 3D software packages, there are lots of videos on making them.

Is it possible to make a thin flat porcelain tile from a plastic pottery body?

Yes. The body is Plainsman M370 (~ 25 silica, 25 feldspar, 30 kaolin, 20 ball clay + talc to tune maturity). It is 3.8 mm thick fired (vs. commercial tiles at 5-7mm). It was rolled (in the plastic state) and dried completely between sheets of plaster board. Bisque and glaze firing were on an alumina shelf in an electric pottery kiln (at 300F/hr up through quartz inversion on the glaze firing). Cooling on both firings was free-fall in a fairly empty kiln. It is flat and flexible enough that I could lay it on the cement floor and stand on it without it breaking! Of course, to produce these consistently special furniture that sinks minimal heat and a kiln that can evenly apply it front and back are needed. This is doable for custom applications. Of course, to compete in the commercial market, they need to be dust-pressed and there are lots of specifications to meet.

Related Information

Links

URLs www.tilecenter.com
Tile Center Inc website
URLs www.tileschool.org
Ceramic Tile Education Foundation website
URLs http://www.ferro.com/Our+Products/Tile+Coating+Systems/
Ferro Tile Frits
URLs http://www.qualicer.org/recopilatorio/ponencias/pdfs/2010234.pdf
Inkjet Printing for Ceramic Tiles
URLs https://en.wikipedia.org/wiki/Saltillo_tile
Saltillo Tile page at Wikipedia

By Tony Hansen


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