Why 3D design and printing is a better way to make slip casting molds

I dread the traditional mold making process, the mess, all the supplies and tools involved. I am a potter, I make functional ceramics. I am not a mold-maker, but 3D design and printing have put it within my reach. This way more fun! There is no stopping this, it’s the future.
-I spend most time on design, pouring the plaster or rubber takes minutes.
-Many fewer tools and supplies are needed, the process is less messy, as easy as downloading a file, printing it and pouring in plaster - this is doable in my kitchen!
-Sanding of flat mating faces is possible (for better seams than I've ever had). This is because natches can be added later (using embeds).
-I can make my own natches and interlock schemes.
-No spare is needed, the 3D-printed pour spouts work better.
-The range of shapes seems limitless. Especially because designs can be split up into pieces, each printed in optimal orientation (and glued together).
-I make molds through multiple design-print iterations. 3D makes do-overs or changes in design as easy as a reprint and plaster pour. So, I can make a mold just to test an idea!

Related Pictures

3D printing artifacts on a bowl model. Are these a problem?

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3D printing is resetting and revolutionizing all fabrication industries. It has taken hold because it brings exciting new capabilities we never had before, especially in ceramics. Each disadvantage is being addressed and solved. This stair-casing, or more correctly, "printing artifacts", are often cited as a reason not to adopt 3D. But these are not an issue here. First, most of the surface on this case mold is not exposed on the final piece. Second, near vertical and fully horizontal printed surfaces, such as the shell around the outside and the spacer ring, don't have artifacts. Third, this bowl model is not 3D printed, it is plaster that was poured into a 3D printed shell. Before use, this will be stuck down onto a potter's wheel and tooled smooth. It is then attached to a clamping baseplate and the 3D printed railing clamped around it.

Bottle calibration mold demos novel casting methods

Plaster molds held together without straps

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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. This method enables aligning halves accurately and then locking them into place.
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. Thus, this mold needs no spare.
3) There are no natches (the halves were poured into disposable 3D printed PLA masters - and mate perfectly and align easily).
These three factors simplify the mold design, reduce mold size, improve the fit of parts and simplify pouring, demolding and cleanup for this specific type of piece.

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!
Glossary	Side Rails Side rails are the containment used when pouring plaster molds. We 3D-print these to custom fit each mold.
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 level. 3D-printed spouts make a spare unnecessary.
Glossary	Mold Natches At digitalfire we are big fans of slip casting and want to help people and companies (even hobbyists) to integrate it into their production.
Typecodes	3D printing problems 3D design and printing for mold making in ceramics bring exciting new capabilities. Awareness of the issues and knowing how to mitigate each is a must. 3D is resetting all fabrication industries and engineers are solving every problem, you can too.

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