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. |
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| 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] |
| Copyright of Ceramics International is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
| Database: | Engineering Source |
| FullText | Text: Availability: 0 |
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| Items | – Name: Title Label: Title Group: Ti Data: Flexi mold slip casting: A novel integration of 3D printing with traditional manufacturing methods. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Anil%2C+Aiswarya%22">Anil, Aiswarya</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> aiswarya.anil2022@vitstudent.ac.in</i><br /><searchLink fieldCode="AR" term="%22Nadimpalli%2C+Raghukiran%22">Nadimpalli, Raghukiran</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> raghukiran@vit.ac.in</i> – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Ceramics+International%22">Ceramics International</searchLink>. Jan2026, Vol. 52 Issue 1, p974-988. 15p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Selective+laser+sintering%22">Selective laser sintering</searchLink><br /><searchLink fieldCode="DE" term="%22Slip+casting%22">Slip casting</searchLink><br /><searchLink fieldCode="DE" term="%22Three-dimensional+printing%22">Three-dimensional printing</searchLink><br /><searchLink fieldCode="DE" term="%22Ceramic+materials%22">Ceramic materials</searchLink><br /><searchLink fieldCode="DE" term="%22Thermoplastic+elastomers%22">Thermoplastic elastomers</searchLink><br /><searchLink fieldCode="DE" term="%22Molds+%28Casts+%26+casting%29%22">Molds (Casts & casting)</searchLink><br /><searchLink fieldCode="DE" term="%22Ceramic+material+manufacturing%22">Ceramic material manufacturing</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: 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] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Ceramics International is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1016/j.ceramint.2025.11.397 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 15 StartPage: 974 Subjects: – SubjectFull: Selective laser sintering Type: general – SubjectFull: Slip casting Type: general – SubjectFull: Three-dimensional printing Type: general – SubjectFull: Ceramic materials Type: general – SubjectFull: Thermoplastic elastomers Type: general – SubjectFull: Molds (Casts & casting) Type: general – SubjectFull: Ceramic material manufacturing Type: general Titles: – TitleFull: Flexi mold slip casting: A novel integration of 3D printing with traditional manufacturing methods. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Anil, Aiswarya – PersonEntity: Name: NameFull: Nadimpalli, Raghukiran IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 01 Text: Jan2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 02728842 Numbering: – Type: volume Value: 52 – Type: issue Value: 1 Titles: – TitleFull: Ceramics International Type: main |
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