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Casting Processes - Ceramic Casting or Plaster Casting (of metals)
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Plaster casting is similar to sand molding except that plaster is substituted for sand. Generally, the form takes less than a week to prepare, after which a production rate of 1-10 units/hr-mold is achieved with a capability to pour items as massive as 45 kg and as small as 30 g with very high surface resolution and fine tolerances.
Once used and cracked away, normal plaster cannot easily be recast. Plaster casting is normally used for nonferrous metals such as aluminium, zinc, or copper-based alloys. It cannot be used to cast ferrous material because sulfur in gypsum slowly reacts with iron. Prior to mold preparation the pattern is sprayed with a thin film of parting compound to prevent the mold from sticking to the pattern. The unit is shaken so plaster fills the small cavities around the pattern. The form is removed after the plaster sets.
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