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That's clay slip. She's using the slip casting technique, which involves filling the mold with liquid clay and then pouring it out. That picture is before she's poured it out. The technique is for making hollow, thin-walled ceramic forms. It requires a plaster mold (which absorbs moisture from the clay slip), which is why she is making a "mold of a mold" and not just simply creating a plastic mold.
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baking *bread :)
I'd agree with everything you said, except that without any insulation and a minimal amount of thermal mass, this oven will probably best suited to pizza, roasting meat/vegetables, etc. Baking break would require a different design, where the heat can be stored in the thermal mass and kept there with insulation. Looks cool either way - enjoy the pizza!
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Or skip the laser printing altogether and just draw the traces on the PCB blank with an industrial Sharpie or nail polish before etching!
There is no way it will be cheaper to have someone else do it. The alternative to ferric chloride is really inexpensive: Muriatic Acid can be had at Home Depot (or local DIY shop) and Hydrogen Peroxide is <$1 at any grocery store. Magazines/catalogs are free and when I used to use this method back in grad school, I just found the cheapest laser printer on craigslist and bought it just for this purpose (I think it was $10). OSH Park is great, but if it's for a single 1-sided board, it's much better to at least take a stab at doing it yourself.
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