INVESTIGATORY PROJECT

Plaster Mold Making for Ceramics Industry

Name of Investigator:
July Louie C. Carba

Instructor :
Engineer Randy K. Salazar

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 ABSTRACT
Plaster mold casting is a widely known manufacturing technique which utilizes
the mixture of gypsum, strengthening compounds, and water to create a mold.
fabricates products with a smooth surface finish and allows for the casting of complex
shapes with thin walls and with less expense than other processes-- mainly the reason
why plaster mold casting is maximized to make gears, lock components, valves,
ornaments, and fittings. This investigative report discusses the procedures and
analyzes the results produced by plaster mold casting based on the video provided in
order to eventually appreciate the technique and to ascertain its significance in the
ceramics industry.

I. INTRODUCTION
A. Background of the Study
Many of the materials seen around us and the objects individuals extensively use
have been made through various mold making processes in the ceramic industry, from
common sculptures to the complex structural components found in infrastructures and
in the household. In this evolving world of art, the techniques of mold making and
casting have served as tools by sculptors and other artists: in both studies that lead to
the final form of an artwork, or as a means of reproducing an artwork (Smart Box,
2017). More so, these processes provide individuals with opportunities for art
expression and appreciation of manufacturing techniques that impart great significance
to people’s way of living.
A widely known manufacturing technique which utilizes the mixture of gypsum,
strengthening compounds, and water to create a mold is plaster mold casting.
According to Thomas Publishing Company (2013), plaster mold casting is a type of
expendable mold process, meaning the molds are not generally reused. It often allows
for the fabrication of more complicated parts. Since plaster has a low thermal
conductivity and heat capacity, the metal in the molds cools slower than in a sand mold,
which lets the metal to fill even thin cross-sections. Furthermore, this process fabricates
products with a very smooth surface finish and allows for the casting of complex shapes
with thin walls and with less expense than other processes-- mainly the reason why
plaster mold casting is maximized to make gears, lock components, valves, ornaments,
and fittings.
This paper investigates the process of plaster mold making as employed in the video
as well as the procedures applied in order to assess the components of plaster mold
casting and how is it a very dynamic and useful technique in the ceramics industry.

B. Rationale and/or Gap Knowledge

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 The main method integrated in this investigation is plaster mold casting. Plaster
mold casting is a manufacturing process that falls under the casting process. It is
distinguished from all other types of casting since it uses plaster as the molding
aggregate instead of sand. Plasters are usually composed of gypsum, lime or cement
with water and sand. Unlike sand, the water inside the plaster leads more fluidity and
contact with the pattern which means, intricate sections and exceptionally good surface
finish can be obtained. This process also works much like other castings processes
where a heated liquid material is poured into a mold that contains a hollow cavity of the
desired shape and then it is solidified. The solidified part is known as a casting (Precise
Cast Engineering, 2015).

C. Statement of the problem/objectives

This investigation intends to introspect the details and methods applied in plaster
mold casting that will eventually ascertain its importance in the ceramics industry and to
conduct a thorough investigative report applying the different concepts learned on how
to make a plaster mold based on the video provided.

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II. METHODOLOGY
B. Treatment/General Procedure
To start the entire process, a line of division was marked in the glass bottle using
the felt pencil. Then a small clay was used to let the glass bottle sit on it. Using the L-
Square ruler, the prototype was placed and measured squarely to avoid undercuts. Few
more pieces of clay were placed around the bottle to surround it until it reached the
dividing line and the right height. Consequently, the layers of clay were softened and
refined in texture using wooden modelling tools.
A small amount of clay was placed at the neck of the bottle to ensure that the
plaster cap will not go inside which might create an undercut. For the dimensions of the
mold, a 1-inch mark was made on the sides, upper and bottom parts of the bottle with
the use of a sharp tool. Excess layer of the clay was then removed using the cutting
tool. excessed layer part of the clay using your cutting tool. A smidgen of cleanser was
then applied to forestall the material to stick.
When the activity was done, estimation was made to get the length and width of
the embellishment box. The boards were put right around the clay. The belt was utilized
to get the boards in holding the form and re-verification was done inside the trim box to
conclude the activity. On the off chance, if there are holes inside utilize the wooden
tools to seal the holes between the clay and the wooden box. The instrument was
utilized to squeeze the leftover dirt to evade spills. As for the arrangement of the plaster,
weigh the amount of water and then multiply by 1.5 the amount of plaster. The plaster
was blended for around three minutes. Then, the plaster was poured in the box making
sure that the plaster was equally at the level of the wooden box. The belt was taken off
and supplanted with flexible bond. After the form was taken off, the outside of the shape
was smoothened up. A scratching plane was utilized to make a chamfer of the form.
After the activity, the clay was taken out. Measuring instrument was utilized to keep an
eye on the line division of the model.
For the final touch, sandpaper was used to smooth the 2nd part of the activity.
Sandpaper number 220 was used to remove a little defect of the mold. After such
activity was done, rehash a similar interaction from the top to reproduce another form
again and again.

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III. RESULTS AND DISCUSSION
A. Result/Findings
Initial Stage

Result after pouring

of the plaster

Middle Stage

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Final Stage

Outcome or result of the

molding process

All the pictures above show the consequence of the strategies in making a mold
on a glass bottle. In the initial stage, putting a clay around the glass bottle serves as the
foundation. It is important to align the clay to the division line to equal the dimension of
the 2nd part. In Middle stage, using sharp instrument, to cut and to remove all the
excess clay. In Final phase, the wooden box must place around the clay and locked it
with the used of belt to hold the wooden box tightly. After that, pouring of plaster would
follow and wait for minutes until the object turns into solid state. Repeat all those
processes to make the 2nd part which is the other side of the bottle, and it's also very

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important to smoothen the layer so the air pockets and holes won’t emerge. Lastly, the
outcome or result of the molding process is achieved as expected.

B. Discussion/Analysis of Data
The result based on the detailed procedure of plaster mold casting as shown in
the video is a two-part plaster mold which was apparently the expected outcome.
Careful application of procedures was done to come up with the right shape, size, and
dimensions of the plaster mold. Right application of plaster mold casting methods is
immensely necessary to come up with the desired outcome and to avoid further
problems that may occur in the process such as leaking, improper gauging or an
erroneous mixture of the plaster. Therefore, the entire video showing the step-by-step
process of plaster mold casting entails the proper simulation of the technique hence it is
an appropriate medium to be modeled by craft makers in understanding the concept of
plaster mold casting.

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Appendix

Casting - Fluid material is filled the mold.

Casting hole- Where all the openings filled with plaster
Division line- it is a line that parts the center and cavity parts of a formed part
Initial Mold-The underlying result of the model of the shape.
Mother Mold- is normally an external, unbending shell that bolsters the adaptable
elastic form assisting it with holding its shape during the packaging interaction.
Chamfer- a balanced inclining surface at an edge or corner.

Standard Procedure:
1) Prepare the glass bottle
2) Mark the bottle with a division line to split two areas
3) Put a clay around the glass bottle until it reaches the division line
4) Place a wooden box and always check the leaks of each side of the box.
5) Seal if there are leaks
6) Smoothen always the object by using sandpaper
7) Preparation of the plaster, 10 pounds of water and multiply by 1.5 for the amount
of plaster. In short, put the plaster to the water.
8) Pour the mixed water and plaster into the molding box.
9) Wait for a dozen of minutes to make your object solid.
10) Repeat procedure to form a two-part plaster.

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References

Precise Cast Engineering (2015). What is plaster mold casting. Retrieved from
https://www.precisecast.com/what-is-plaster-mold-casting/
Smart Box (2017). History of mold making and casting. Retrieved from
https://smartartbox.com/blogs/smart-art-blog/history-of-mold-making-and-casting
Thomas Publishing Company (2013). All about plaster mold casting - what it is and how
it works. Retrieved from https://www.thomasnet.com/articles/custom-
manufacturing-fabricating/all-about-plaster-mold-casting/#:~:text=During
%20plaster%20mold%20casting%2C%20the,plaster%20fills%20the%20pattern
%20completely.

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