CAD drawing of handle mold (spareless)

Available as a Product on the Downloads page

I have long wanted an easy way to make molds for slipcasting handles that mate perfectly to specifically shaped and sized mugs (or pitchers, teapots, etc). These are the answer. These shells print quickly to only 11 grams of PLA filament. They peel away from the set plaster with a heat gun to give fine detail and a perfect fit. These use 3D-printed pour spouts instead of a mold spare (printed separately) and enable cutting the joint surface cleanly and accurately before the handle is removed from the mold (a version of this is also available with spares). This is the product of a long development process. This drawing is available on the downloads page.

Worried about mixing or tuning your own casting slip recipe? We have lots of help on doing that. As motivation, consider the benefits of mass producing handles and store them in a wet box with the attachment slip.

Available as a Product on the Downloads page

Related Pictures

CAD drawing for 3D-printing plaster mold natches, spacers, clips and embeds

Available on the Downloads page

Plastic natches are cast into plaster molds to provide a durable and good-fitting interlock to ensure pieces line up perfectly. The traditional one familiar to most people is the 3/8" or 9.5 mm size (nipple diameter). Because of issues surrounding their use (not the least of which are price or even finding a supplier), we designed and print our own using PLA filament. Ours have several advantages:
-There is never an issue with supply, we make them.
-13.5mm holes in case molds are all that is needed to adapt to these.
-3D printing case and block molds necesititates pouring plaster and rubber into shells with planar mating surfaces downward (they must sit flat on the table). The thin flanges on these cause minimal issues.
-Casting an embed into a mold is more flexible since we can glue (or friction fit) a natch or a spacer inside. In addition, they permit flat mating surfaces to be sanded (for better flatness and fit).
Our drawing (right) shows the measurements we use. 3D printing is precise enough that the inside dimension of the embed is the same as the outside of the natch shoulder, yet the natch slides in perfectly. The same good fit happens with the clip and embed and the natch nipple and spacer (although it is necessary to chamfer the bottom corners and bevel the top corners of the spacer for better insert).
There is a good chance some dimension changes are needed to fine-tune for printing in your circumstances. Since these are printed in batches of many, failed print jobs will result if insufficient attention is given to this (and to whether to use a glued plate).

3D printed three-piece jigger case mold complete

Available on the Downloads page

It is now practical to make true-round, perfect-fitting, all-in-one case molds for jiggering using a consumer 3D printer and PLA filament. This was a one-off test mold to demonstrate the method but these print so fast this is suitable to make dozens of molds. The process: Create the drawing in 3D CAD (e.g. Fusion 360), print the three sections, glue them, turn the assembly upside down, fill with plaster, let it set and peel out the inside two pieces using a heat gun.

Things to note:
-The outside diameter can be adjusted to fit the ring on any jigger machine or cuphead.
-This is very light and prints quickly, the walls are only 0.8mm thick.
-The shoulder (C) is printed solid and the PLA printed surface from A to D is left in place permanently, this enables precise and durable fit into the cuphead. I print the outside shell upside down, so no printed support is needed.
-The down-pointing flange (A) embeds it into the plaster providing a durable edge against which to fit the pour spout (F). The glue joint connecting A & B breaks when B & E are removed.
-B and E are printed upside down, no support is needed for B, since the top is open, it thus prints quickly.
-The base E has a flange that enables gluing it precisely into B. Debossed logos are practical. It prints upside down for maximum quality (print support is generated but because it is short it prints quickly).

You can get this on the downloads page.

CAD drawing of handle mold with traditional spares

Available on the Downloads page

This mold creates traditional spares (instead of 3D-printed pour spouts on our alternative design). We print these using PLA filament. After extraction from the mold the spares on the clay handles need to be cut away carefully, using a sharp fine-bladed knife.

Worried about mixing or tuning your own casting slip recipe? We have lots of help on doing that. As motivation, consider the benefits of mass-producing handles and storing them in a wet box with the attachment slip - they will be ready to use whenever needed.

Links

Media	Drawing a Mug Handle Mold in Fusion 360 Lilly will take you step-by-step through the process of drawing a shell mold that can be 3D printed and used to cast a plaster mold for slip casting perfect-fitting handles.
Glossary	Casting Slip Casting slips are among the easiest clay bodies to make yourself. The ability to make and tune your own will open many doors in your production process.
Projects	Mug Handle Casting

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