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Beer bottle calibration mold demos some casting process improvements

This is another example of the flexibility potters have compared to manufacturers. These 3D-printed gizmos are stuck on to hold the mold halves together. The casting slip itself adheres them. Dipping the flat surfaces and attaching them takes seconds. The 3D printed pouring spout is likewise attached using the slip (it also helps hold the mold halves together). Another feature: There are no notches (the halves were poured into disposable 3D printed PLA masters - and mate perfectly). Initial use of a rubber band to hold them together was not ideal because realignment of the halves damaged the inside corners. By using this method the mold halves can be aligned accurately. These three things are great for potters. They simplify mold design and production, reduce mold size, improve the fit of parts and simplify pouring, demolding and cleanup,

Plaster molds held together without straps

Related Pictures

A 3D-printed spout enables a flared rim on cast ware

Tap picture for full size and resolution

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 that resists warping, 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.

A 3D-printed pour spout in place on the top of a mug mold

Tap picture for full size and resolution

I prepare to attach these by simply touching them to the top of the slip (it is sticky and coats the underside evenly). Then it is just a matter of setting it in place and and it glues down in seconds. I make these a little larger diameter than the top of the opening (e.g. 2mm) in the plaster mold, producing a small overhang on the cast piece. During the time in the mold, the clay slurry creates a thickness against the plaster walls but also extends upward above the top of the mold (inside the spout). A while after pour-out I am able to make a cut and lift the spout away leaving an over-hang, over-height and thickness that all play to enable jiggering the rim to the exact contour I want.

Links

Glossary Slip Casting
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.
Projects Beer Bottle Master Mold Project
A project that took several years of failures and blind allies and is finally coming together - so much simpler than expected!

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