Ceramic Workshop: Plaster Mould Making (part III)

Production process

I: Building up the clay base
To begin this part of the production, I first built up the top of the plaster mould with clay to a height of about 2-3 cm. This step is to ensure that the poured clay paste is deep enough to form the structure of the lid and to prevent the clay paste from overflowing when poured.

II: Introducing and pouring the clay slurry
Next, I slowly introduced the mixed clay slurry into the freshly constructed clay base. After pouring, I left it for 20 minutes to allow the clay slurry to initially cure in the mould. This waiting time was set based on previous experience to allow the clay slurry to reach a sufficient hardness without being so hard that it would be difficult to handle.

III: Filtering the excess clay slurry and stripping the moulds
Once curing was complete, I carefully backed up the mould to allow any uncured excess clay slurry to flow out. This step is to ensure that the lid is of uniform thickness, while avoiding an overly thick bottom that will affect the beauty and practicality of the final product. I let the moulds sit for 3-4 hours to ensure that the clay is thoroughly hardened, and then I begin to release the moulds. Demoulding is a process that requires extreme care, and any impatience could result in a broken finished product.

Four: Carving out the details
Once the mould is off, I use a special carving tool to carve details into the semi-dry ceramic lid. This step is not only a technical challenge, but also a process of artistic creation, giving the product personality and style through detail carving.

Reflections and challenges:
1. Challenge of technical precision: Maintaining precise thickness and uniformity is the biggest challenge in the process of building up the clay base and pouring the clay slurry. Any negligence may affect the quality and aesthetics of the lid.

2. Importance of time control: Controlling the timing of each step is crucial to the successful production of plaster moulds, especially the curing time of the clay slurry and the timing of demoulding.

Through this lid making, I have not only deepened my understanding of ceramic making techniques, but also improved my ability to control the whole production process. Each step of the process requires precise handling and a deep understanding of the behaviour of the material.