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Flexi mold slip casting: A novel integration of 3D printing with traditional manufacturing methods.

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Title: Flexi mold slip casting: A novel integration of 3D printing with traditional manufacturing methods.
Authors: Anil, Aiswarya1 (AUTHOR) aiswarya.anil2022@vitstudent.ac.in, Nadimpalli, Raghukiran1,2 (AUTHOR) raghukiran@vit.ac.in
Source: Ceramics International. Jan2026, Vol. 52 Issue 1, p974-988. 15p.
Subjects: Selective laser sintering, Slip casting, Three-dimensional printing, Ceramic materials, Thermoplastic elastomers, Molds (Casts & casting), Ceramic material manufacturing
Abstract: This study introduces an innovative and effective ceramic slip casting technique that utilises powder-based 3D printed flexible molds made from Thermoplastic Polyurethane (TPU) through Selective Laser Sintering (SLS). Unlike traditional Plaster of Paris (POP) molds, SLS-printed TPU molds represent a transformative advancement in ceramic manufacturing by offering enhanced design flexibility, superior reusability, and controlled porosity for uniform drying, overcoming several limitations of conventional mold materials. The inherent microporosity of TPU supports controlled water removal during casting, enabling uniform drying of high-solid-loaded alumina slurries. Surface characterisation revealed adequate wettability and moderate surface roughness, both essential for uniform slurry adhesion and defect-free demolding. The 3D-printed TPU molds exhibit excellent reusability, withstanding multiple casting cycles without degradation. Various mold configurations, such as single and three-piece molds, were utilised to demonstrate versatility. Sintering of cast alumina ceramics at 1300 °C, 1450 °C, and 1550 °C showed linear shrinkage of 10%–15% and volumetric shrinkage of 30%–35%, which falls within or slightly above the typical ranges reported for traditional slip casting (usually 8%–12% linear and 25%–30% volumetric), indicating effective densification and microstructural integrity. Remarkably, a maximum sintered density of 98.5 ± 0.5% was achieved at 1550 °C, accompanied by structural integrity. This method significantly enhances both the process efficiency and the quality of ceramic components. This integration of additive manufacturing with traditional slip casting presents a scalable and repeatable approach for defect-free, high-density ceramic components, positioning 3D printed TPU molds as a next-generation tool in advanced ceramic fabrication. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:This study introduces an innovative and effective ceramic slip casting technique that utilises powder-based 3D printed flexible molds made from Thermoplastic Polyurethane (TPU) through Selective Laser Sintering (SLS). Unlike traditional Plaster of Paris (POP) molds, SLS-printed TPU molds represent a transformative advancement in ceramic manufacturing by offering enhanced design flexibility, superior reusability, and controlled porosity for uniform drying, overcoming several limitations of conventional mold materials. The inherent microporosity of TPU supports controlled water removal during casting, enabling uniform drying of high-solid-loaded alumina slurries. Surface characterisation revealed adequate wettability and moderate surface roughness, both essential for uniform slurry adhesion and defect-free demolding. The 3D-printed TPU molds exhibit excellent reusability, withstanding multiple casting cycles without degradation. Various mold configurations, such as single and three-piece molds, were utilised to demonstrate versatility. Sintering of cast alumina ceramics at 1300 °C, 1450 °C, and 1550 °C showed linear shrinkage of 10%–15% and volumetric shrinkage of 30%–35%, which falls within or slightly above the typical ranges reported for traditional slip casting (usually 8%–12% linear and 25%–30% volumetric), indicating effective densification and microstructural integrity. Remarkably, a maximum sintered density of 98.5 ± 0.5% was achieved at 1550 °C, accompanied by structural integrity. This method significantly enhances both the process efficiency and the quality of ceramic components. This integration of additive manufacturing with traditional slip casting presents a scalable and repeatable approach for defect-free, high-density ceramic components, positioning 3D printed TPU molds as a next-generation tool in advanced ceramic fabrication. [ABSTRACT FROM AUTHOR]
ISSN:02728842
DOI:10.1016/j.ceramint.2025.11.397