Step 1: Creating Ceramic Forms in Rino
For vessel 1, I started out with creating a profile line for the form. From this it was a simple matter of using the "Revolve" command to create a 360 degree profile of the line. After this the last step is to "cap" the form so you can create a mould from the closed surface.
For vessel 2, I used polygons to create the forms. I took several polygons and layered them then "lofted" the sides. This created the polysurface vessel form that I wanted. I then used the "cap" command to seal the form.
From here I constructed planes for each vessel. These act as the place that the object will be milled out on. Each plane needs to have matching keys and have at least a 1.5 inch distance around the object for slipcasting.
Step 2: CNC Milling
Step 3: Mould Making
1. Prepare plaster mixing materials:
a. Clean all surfaces
b. Gather plaster, water, mould soap, cottle boards, clay, Vaseline and scrapers.
2. Build walls around object for moulding using cottle boards.
3. Seal ALL areas with clay on the inside and outside of the mould surface
4. Mould soap all surfaces coming into contact with the plaster thoroughly and use Vaseline on the cottle boards
5. Calculate the amount of plaster and water needed
6. Follow Andy Martin's chart for adding/mixing/poring plaster
7. Allow mould to dry then remove cottle boards and clean up/scrape the mould
8. Let mould dry for between 2-5 days
Step 4: Slip Casting/Press Moulding
1. Use straps to secure your mould tightly together
2. Pour casting slip into mould and allow to sit to build up wall thickness
3. Pour out remaining slip then let the cast piece sit in the mould for at least 15 minutes
4. Remove straps and carefully take apart mould and release cast piece
1. Press wedged clay into the the mould either as a slab or as coils
2. Use rubber rib to smooth out surface of the clay and achieve uniformity
3. Let clay set up for at least 15 minutes then release from the mould
4. From here slip and score the edges to attach to the other moulded piece (two half's)
Step 5: Firing
Step 6: Ceramic Decals
1. Decide where the decal will be place. Be aware that decals do not do well over compound surfaces, so flat planes or small sections are best.
2. Cut out decal carefully from the sheat
3. Place decal in shallow bowl of water to remove the paper backing
4. Carefully remove decal from backing and place on the ceramic surface
5. Squeegee the excess water and air from the decal using a RED Mudtool rib
1. Use manual kiln
2. Place objects into the middle of the kiln with a cone pack (Cone 017) in clear visibility of a peep hole
3. Place soft brick under the lid to prop it open
4. Turn up all knobs to "low"
5. After 1 hour turn all knobs up to "medium"
6. After 1 hour turn all knobs up to "high"
7. Wait until you see color in the kiln then remove the soft brick
8. At this point wait at the kiln until you see the first cone in the cone pack (cone 018) drop.
9. Once the cone drops turn off all the knobs and allow the kiln to cool
Step 7: Resources