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  Making Ceramics Products
MORE ON 'HOW TO'  by MASTERLINE MOLDS

HOW TO MAKE CERAMIC PRODUCTS
HOW TO MAKE CONCRETE PRODUCTS
HOW TO MAKE PLASTERWARE PRODUCTS

Filling a ceramic plaster mold with clay slip

Stacks of greenware ready for fettling, wet sponging, then firing

Manufacturing ceramics begins with a plaster production mold often referred to as a Ceramic Mold and clay in the form of slip.  After securing the mold with straps or strong elastic bands, slowly fill the mold with slip.  Allow enough time (normally 20 to 25 minutes produces a clay thickness of 3/16 of an inch) for the slip to begin forming a clay body on the inside of the mold.  During this time, monitor the level of the slip in the mold and periodically top-off or add more slip.

Larger pieces, such as floor vases, table lamp bases, etc. will require more time to form a thicker clay body.

At the appropriate thickness (use a timer), the unused slip is emptied.  The mold is then turned upside down and continues draining.  This method of casting is known as 'drain-casting' and is still the most popular and efficient way to cast molds.

The same methods are used for casting  earthenware, stoneware, porcelain or red clay slips.

The plaster in the production mold continues to draw the moisture naturally from the clay.  After some time, usually 45 to 60 minutes later, the clay body begins to pull away from the plaster wall of the mold.  This releasing action occurs because the clay body now has less moisture in it than the plaster mold.

At this point, the new casting may be removed from the mold.  Release the straps or bands holding the mold together, and gently pull on the wet clay body or release the clay body by carefully tapping on the mold.  The term greenware refers to the newly cast piece of clay as it is still quite tender, soft, and fragile and will break, tear, or distort easily.

After the greenware has dried, it is lightly sanded or 'fettled' with a knife to remove all the mold parting lines.  After the fettles have been removed the piece is further wet sponged to smooth the surface.  The seam lines or fettles are formed where two sections or pieces of the mold come together.  The semi-skilled person who removes these lines on thousands of pieces each week is known as a 'fettler'.

With the piece professionally cleaned, the greenware is now ready for its first firing to around 2000 F. degrees.  The purpose of this fire is to mature the clay body to produce bisque which is also known as biscuit ceramic ware.

At this point, a coat of glaze is applied to the piece, both on the inside and outside of the piece either by brushing, dipping, pouring, or spraying. The glaze (similar to those found in glass making) is suspended in water. After the piece has been glazed it is fired a second time to melt and mature the glaze. 

After the piece has been glazed-fired,  or glost fired, the item may be further enhanced by applying fired-on ceramic decals for added decoration, or applying a coat of mother of pearl or a lustre, or decorating using 22K gold.

Making a piece of finished ceramic is quite labour intensive.  Sometimes the costs can be too high for the market, especially if the factory experiences heavy losses during the manufacturing process.

Ceramic is very popular and everyone's favourite because of its many properties.  For example, you can cool a ceramic stein in the refrigerator and it will stay cold for some time, or warm plates and dishes in the oven or dish washer before serving a hot meal.  Ceramic ware can be used safely in conventional ovens, microwaves, or convection ovens.

And when red clay wine coolers are soaked in water it will act as a cooler on a hot summer's day, or when soaked in water red clay disks will keep all your brown sugar and dried fruit at their perfect moisture content.  And clay cookers offer perfectly cooked roasts, especially fowl. There are many, many uses for ceramic for today's life style.  These are just a few of its uses.


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This page was last updated on October 06, 2007