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Bottle calibration mold demos some casting process improvements

Three slip casting methods are examples of the flexibility potters have compared to manufacturers (especially for small molds like this).
1) 3D-printed locks are stuck on to hold the mold halves together. The casting slip itself adheres them. Dipping the flat surfaces and attaching them takes seconds. By using this method the mold halves can be aligned accurately.
2) The 3D-printed pouring spout is also attached using the slip (it also helps hold the mold halves together) and acts as a reservoir and pour-out indicator.
3) There are no notches or natches (the halves were poured into disposable 3D printed PLA masters - and mate perfectly and align easily).
These three factors simplify mold design, 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


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.

Links

Glossary Pour Spout
Plaster molds intended for slip casting have a spare at the top to act as a reservoir. This enables overfilling the mold to accommodate the dropping slurry left. 3D-printed spouts make a spare unnecessary.
Glossary Slip Casting
A method of forming ceramics. A deflocculated (low water content) slurry is poured into absorbent plaster molds. As it sits in the mold, usually 10+ minutes, a layer builds against the mold walls. When thick enough the mold is drained.

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