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Slip cast leather-hard full-sized beer bottle

This is a black buring porcelain (it has 10% raw umber), the L4768D recipe (I also use a red burning one, the L4558A recipe). As a starting point I use water/Darvan proptions outlined in the "Casting Recipe" section of the M370 data sheet. This piece is leather hard, just out of the mold. By the time it is fired it will be 10% smaller and will match the glass one on the right. The pads are positioned firmly and correctly for the swing-top stoppers. These are presenting few problems, I am making bottles by the dozen (from multiple molds). The narrow neck causes issues for fast-casting clays if drained too quickly - inverted draining creates suction that can pull the soft walls away from the plaster. I made a large 3D printed pour spout to provide a reservoir to accommodate the fact that the slurry level drops during casting, that turned out to be a double benefit because it acting as a gauge of when the drain.

Slip cast beer bottle

Related Pictures

Finished cast v1 stoneware beer bottles


Cast ceramic beer bottles

The center bottle is a standard glass one, the other two are ceramic, cast out of the version 1 plaster mold. The stopper fits perfectly. The clay is Plainsman M370 + 10% raw umber, it fires black. The glaze is GA6-B. They were fired using the C6DHSC firing schedule. The slightly larger size will enable inserts at the bases to inlay a logo or other info. These bottles are a testament to how 3D printing and 3D design now make it possible for even casual potters to make pieces never before practical or even possible.

Version 2 ceramic beer bottle block mold


Casting a rubber case mold for the beer bottle

This time I printed the block mold, rather than the case mold, in six pieces on my consumer 3D printer.
Top: I printed the two halves upright (creating them in the slicer rather than Fusion 360). Because the print lines run concentric the quality is so much better than the previous version printed flat. The ribbing inside made the halves strong so they did not go out of shape when filled with plaster (to give them weight).
Second: The mold halves were simply laid against each other - they mated perfectly (and stayed in place because they are full of plaster). The four rails were then clamped in place.
Third: The PLA was soaped (using Murphy's Oil Soap) and rubber poured in (Smooth-On PMC-746). The next day it easily pulled out.
Fourth: The finished rubber case mold. The sides are pretty flabby so I make them rigid using the four rails (placed upside down).
Right: Using a plaster mold created from this rubber case mold I slip-casted a bottle using my L4768D recipe, glazed it with GA6-B and fired it at cone 6.

Links

Projects Beer Bottle Master Mold via 3D Printing
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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