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A method to make a two-part slip casting mold in one pour

This is part of a project to create a new mold. I have to make various iterations to arrive at a final design where rubber will be used to make the case mold. But until then I will 3D print the case mold directly. Here are some features that make this super cool:
-The center section is the jug being cast (two pour spouts will be glued on). It is hollow and will be split horizontally in the slicer so the two halves can be printed with open side up and then glued together (with the aid of printed inner hoops to align them).
-The mold seams, where the two halves mate, is printed as a 0.4mm membrane connected to the model and running vertically down its center.
-The membrane has 9.4mm holes for the insertion of standard mold natch pairs. During plaster pour the membrane will flex somewhat, this will be a benefit to aligning the halves.
-The outer shell halves have no angles steeper than 45 degrees and thus print without printed supports. The flanges were drawn using our rotation technique (see link below).
-The round flat base will be glued onto the bottom disk.
-Any rough surface sections of the model (printed on top of support), will be coated with a fluid epoxy to smooth them.
-A separate handle mold will be made.

Complete case mold done in one pour of plaster

Related Pictures

3D-design a flange for clamping a shell mold


Flange on 3D jigger mold

This type of shell enables holding the mold together with paper clamps, making for easy removal when plaster is set. Here is the simplest way to draw it.

-Draw the jigger mold profile like shown below left (we use a 0.8 thickness outline).
-Draw another 6-8 mm outside it, that will be the flange.
-Revolve the mold profile 359.5 degrees, leaving a small gap, perhaps 0.5mm.
-Rotate the flange (with join operation) 0.5 degrees (hopefully producing 1mm thick, adjust as needed).
-Rotate the flange again (with join), but in two sides of -1.0 and 0.5 degrees (creating the other flange).

Notice the details that enable printing this upside down without generating any printed support. The printed PLA is left on the plaster mold above and below the shoulder, enabling precise fitting and good wearability.

Links

Projects 2019 Jiggering-Casting Project of Medalta 66 Mug
My project to reproduce a mug made by Medalta Potteries more than 50 years ago. I cast the body and handle, jigger the rim and then attach the handle. 3D printing made this all possible.
Projects Medalta Ball Pitcher Slip Casting Mold via 3D Printing
A project to make a reproduction of a Medalta Potteries piece that was done during the 1940s. This is the smallest of the three sizes they made.
Glossary All-in-one case mold
A method of 3D printing the case mold shell of an entire assembled plaster mold for using in ceramic production.

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