The slip on the right has way too much Darvan deflocculant. Because the new recipe substitutes a large-particle kaolin for the original fine-particled material, it only requires about half the amount of Darvan. Underestimating that fact, I put in three-quarters of the amount. The over-deflocculated slurry cast too thin, is not releasing from the mold (therefore cracking) and the surface is dusty and grainy even though the clay is still very damp. On my second attempt I under-supplied the Darvan. That slurry gelled, did not drain well at all and it cast too thick. On the third attempt I hit the jackpot! Not only does it have 1.8 specific gravity (SG), but the slurry flowed really well, cast quickly, drained perfectly and the piece released from the mold in five minutes. Interestingly, on a fourth mix I made an error, putting in too much water, getting 1.6SG. The casting behavior was similar to the over-deflocculated slip (even though the Darvan content was much lower). A good casting slip is a combination of a good recipe, the right SG and the correct level of deflocculation.
The deflocculation process is the magic behind the ceramic casting process. It enables you to make a slurry of far lower water content and thus lower shrinkage.
A method of forming ceramics where a deflocculated (low water content) slurry is poured into absorbent plaster molds, forming a layer against mold walls, then poured out.
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