Click here for information about DIGITALFIRE Corporation

Monthly Tech-Tip from Tony Hansen

I will send practical posts like these (from thousands I maintain). No ads or tracking. We are troubleshooting the confirm email, for now you will be subscribed immediately (the first monthly email will provide one-click unsubscribe).


Blog

Oversize Particles Simple Test

Oversize ceramic materials particles on 150 mesh screen

This is simple test can be done to determine if oversize particles are present in a raw material to be used for clay body manufacture. While materials are sold as minus 200 mesh, as you can see here, they don't even pass at 150 mesh. In each case, we have attempted to wash through 50 grams of the powder (using the technique of our WSR test).

All ceramic materials must be ground using particle size reduction equipment. This process enables removal of contaminants or reducing their size enough that they do not marr the fired surface of the body. This is a demanding task. Being able to measure it quickly enables spotting problems with a materials shipment (and therefore how well a supplier meets their quality obligations and the kind of product that can be made using it). Ball clays and kaolins are the most problematic, not just in particle size and contaminating particles but also fired color and plasticity.

Of course, a record of this needs to be kept. That is where your account at Insight-live.com comes in. Upload pictures like these or just make a note of the result.

Context: Wet Sieve Residue, Watch out for iron..

Tuesday 1st July 2025

v6 Beer Bottle Drawing

Fits standard swing top stoppers.

Available on the Downloads page

3D printed case mold for making ceramic beer bottles

3D print this, pour in plaster to make a slip casting mold! My previous work on this project assumed a smaller 3D printer (making it necessary to print flanged PLA mold sections that clip together). But larger 3D printers are now common, making the CAD work much easier. This drawing is parametric for height, body diameter, wall and plaster thickness, and neck height (for the full bottle set body=160mm, neck=96). This uses my standard clips and embeds (upper right). Neck vertices are proportional to height, so resizing works well. The top end is filleted to permit the longest possible mold on the print bed (diagonally). The bottom inside perimeter is chamfered, strengthening the default 0.8mm side wall junction to the base (that being said, be careful when removing it from the print bed, flexing too much will cause failure here).

Doing this smaller size is for prototyping and testing. Note that casting plaster on a 3D print creates artifacts (which will appear as wood grain, lower right), later I will create a hybrid plaster/PLA or rubber case mold. This PLA mold prints quickly, it has a hollow back side, permitting easy removal with a heat gun. There is no spare, it employs a pour spout, making the mold shorter and producing a better lip.

Need a stoneware slip casting recipe? L4768E or L4768H are a good choice. A glaze recipe? How about GA6-B (or similar)? Go full DIY with this, you will never turn back.

Context: Swing Top Stopper Mechanism.., A 3D Printed Mold.., DIY natches spacers and.., Beer Bottle Master Mold..

Monday 30th June 2025

A 3D Printed Mold Spout

Better Than a Spare for Slip Casting

Available on the Downloads page

A plaster mold pout spout

Glue one of these on top of your slip casting mold (using slip) and enjoy the many benefits. These are intended for people who make their own molds using the 3D printing techniques taught on this website. Among the advantages are the following:
-Less mess.
-Smaller, simpler molds (they don't need a spare).
-Overhung lips, more precise lips.
-Visible indication of casting progress.

Context: v6 Beer Bottle Drawing.., Pour Spout

Sunday 29th June 2025

20 Skids of Material Just arrived

Fearful Freddie doesn't know what to do!

Fatique Freddie is overwhelmed by incoming material

Fatigue Freddie is scared he will to be the scapegoat if this load of incoming material if off-spec again. Production wants to start using it tomorrow. This stuff has not been consistent and customers have been unhappy. He doesn't know where to start. Management thinks there is no way to test all the runs they make so he knows this is the place to do it, when materials come in. But he's alone, there is no cooperation between production, sales, QC in feeding info into any kind of record-keeping system. His company doesn't take responsibility for product quality variations resulting from material variations.

Minimal testing: Give the shipment a new code in the recipe area of Insight-live. Enter what is known. Upload a picture of any certificates provided with it. Are all the pallets lot numbered? Record that in the notes. Are they all the same lot? Record that. Are the pallets sequentially numbered? Test one from each lot for oversize particles (very important for clays). Make an SHAB test bar also, get it/them dry (in the dehydrator) and into the kiln overnight.

Context: Wet Sieve Residue, Protect your reputation as..

Thursday 26th June 2025

Absolutely Jet-Black Cone 6 Engobe on M340

The could also be super white

A buff stoneware mug with black engobe

This is the L3954B engobe. 15% Mason 6600 black body stain has been added (instead of the normal 10% Zircopax used for white). Of course, a cover glaze is needed for a functional surface. We put a lot of development work into producing a recipe fits this body, M340. It works even when thickly applied because it has the same fired maturity as the body. Lots of information is available on using L3954B (including mixing and adjustment instructions). Engobes are tricky to use, follow the links below to learn more. L3954B is designed to work on regular Plainsman M340 (this piece), M390 and Coffee Clay. Most important we document how to adjust its maturity, and thus firing shrinkage, to fine tune fit if needed. These bodies dry better than porcelains and are much less expensive, so coating them with an engobe to get a surface like this makes a lot of sense. Ed Phillipson discovered this 80 years ago, enabling selling ware made from these clays as white hotel ware.

Context: Mason 6600 Black Stain, L3954B, L3954J black engobe on.., How to make a.., Here is why porcelain.., How to test if.., Stained engobes can be.., The L3954B engobe page.., Thixotropy, Engobe

Wednesday 25th June 2025

In-plaster Anchors With Threaded Inserts

Available on the Downloads page

M3 3D printed threaded inserts for plaster

These brass/plaster pyramids embed into plaster to provide a threaded hole that M3 bolts can screw into. That enables attaching 3D printed elements to plaster elements when making hybrid molds. Narrow inserts permit placement in cramped spaces and nearer edges.

These are made possible using M3 brass knurled nuts and M3 bolts that can be purchased on Amazon. The brass nuts can be pressed in using a soldering iron. The pyramid-shaped 3D-printed anchors are 13mm high, they will accommodate 12mm, or less, inserts (the longest ones in the kits shown here bottom left). The holes are 4.4mm dia at the top and taper inward at -2 degrees. Of course, you can adjust sizes and angles as needed for your application.

Context: Hybrid plaster 3D printed..

Wednesday 25th June 2025

The amazing power of 1% talc:

It accelerates the vitrification of this stoneware

1% talc added to a clay body

These two unglazed pieces are made from the same clay, M340. They are fired at the same temperature. But the one on the right has 1% talc added. Greying of the color is a characteristic visual change as this clay body transitions into the vitreous state we target. That transition happens over a narrow temperature range. Because the raw materials naturally vary in the temperature at which they vitrify, we have to tune the recipe so that the transition happens from cone 5 to cone 6. It is accompanied by a drop in porosity of 2% or more (according to our SHAB test). Talc acts as a catalyst for this change; in this case, only 1% is needed. By itself, talc is refractory. Yet it acts as a flux here! The fact that it can effect this big of a change with only 1% is amazing. Interestingly, this phenomenon only occurs with tiny talc additions.

Context: Talc, Vitrification

Wednesday 25th June 2025

TPU vs PLA Filament for Mold Making

TPU vs PLA for mold making

The mold on the right is PLA filament. Printed at 0.8mm thickness, it only weighs 38g yet is very strong. It removes easily from the plaster with a heat gun. The TPU flexible mold weighs 62g (the walls are 1.6mm thick) but it will need a PLA shell to hold the walls vertical (or far thicker walls). It took four attempts to print this. The surface quality is not nearly as good, especially on the top layers. Printing is much slower.

PLA is a bioplastic, made from renewables. It can potentially be composted. PLA is the most common type of filament used in FDM 3D printing. It has a low melting point, which eases printing and improves interlayer adhesion (but heat resistance of printed products is poor).

Regarding TPU, here is some advice from a follower (who uses a Prusa printer and gets better results than us): "The secret to printing with TPU is constant speed while printing. Under Print Settings, go to Speed. Set them all to 20 mm/s. Ironing will be greyed out unless you have it on. Then, in the next section, Dynamic Overhang Speed, set everything to 20 mm/s. Under Modifiers set First Layer Speed to 20 mm/s. Then under Auto Speed (Advanced), set Max Print Speed to 20 mm/s. This will prevent almost all webbing and other print issues. Some people also suggest reducing the Z-Axis Nozzle Retraction, but I have not found a need to do that."

Context: PLA 3D printer filament..

Monday 23rd June 2025

DIY clay bodies via slurry mixing:

Consider the advantages.

Consider the advantages of making your own clay bodies using a propeller mixer and plaster table.
-Independence: You control product availability, quality and consistency.
-Flexibility: You control the recipe (with our help if needed). Fine-tune and adjust it over time to fit your needs and compensate for variations in material properties and supply.
-Special-purpose clay bodies are possible, ones that ceramic suppliers do not or cannot make.
-The slurry up process achieves better mixing and deairing than any pugmill. No aging needed.
-A mixer and plaster table are useful for so many other things in a pottery studio.
-Achieving the right stiffness is an integral part of the process.
-Recycling scrap, by slaking, fits the process.
-Local native clays: Slurries enable the use of a magnet to remove iron, a sieve to remove particulates and a settling process to remove soluble salts.
-Cleanup is easy so many kinds of clay can be made without cross contamination.
-It is rewarding - you will own the whole process, the bragging rights alone make it worthwhile for me!

Context: Formulating a Porcelain, Formulating a body using.., Testing your own native.., Slurry Mixing and Dewatering..

Thursday 19th June 2025

Medalta Ball Pitcher Mold v10

Using 3D prints and plaster to make a hybrid

This is version 10 of my Medalta ball pitcher case mold. I am still determined that a standard 3D printer with PLA filament brings complicated molds within reach of almost any potter or hobbyist willing to learn 3D design. The project has evolved to become hybrid, using both plaster and 3D prints in the final mold. Two views of the PLA prints needed to pour a plaster half-model are shown at the top.
-Plaster is poured into A.
-I attach threaded anchors to the underside of the baseplate C (using bolts through the small inner holes), they hold the plate firmly in place on the plaster half-model.
-B is a spacer, it is clamped to the underside of C (and aligned using bushings in the holes), it is only used during the model pour.
-Bottom: A is on a perfectly flat and level surface. It was filled with plaster just to the rim and then the baseplate was placed on top of it (the spacer acting to correctly position it). More plaster was added and a few minutes after this it was scraped off flush.
After hardening the spacer can be removed, the mold peeled off using a heat gun, and the plaster surface finished and soaped. The 3D render also shows one of the side rails, D. It holds in place by a flange that wraps under and locks into the holes (the last version used magnets; this approach has several advantages over that).

Context: Custom-printed rib smooths this.., Medalta Ball Pitcher Slip..

Friday 13th June 2025

Contact Me

Use the contact form at the bottom on almost all the pages on this site or let's have a together.

Other ways to Support My Work

Subscribe to Insight-Live.com. It is about doing testing and development, not letting the information slip away. Starts at $15 for 6 months.

Help Me on Social

Tony Hansen
Follow me on

Test, Document, Learn, Repeat in your account at insight-live.com

Login to your online account

Chemistry plus physics. Maintain your recipes, test results, firing schedules, pictures, materials, projects, etc. Access your data from any connected device. Import desktop Insight data (and of other products). Group accounts for industry and education. Private accounts for potters. Get started.

Conquer the Glaze Dragon With Digitalfire Reference info and software

Download for Mac, PC, Linux

Interactive glaze chemistry for the desktop. Free (no longer in development but still maintained, M1 Mac version now available). Download here or in the Files panel within your Insight-live.com account.


What people have said about Digitalfire

  • We were at a friend's place whom had purchased the book "The Magic of Fire," and were both very impressed by the book - so I wrote down the web address and went to your site when we got home.
  • All your info on glaze chemistry and material characteristics are very informative and great catalysts for pushing me to take things a bit further. Most appreciated.
  • I have been working as research assistant for the design of continous type microwave dryer for ceramics. Thank you for the infomation provided.
  • Your site is one of the most unusual sites I have encountered since I began exploring ceramics on the web. I am a student in a 2 year pottery program, and would like nothing better than to understand glazing from the very beginning of my career as a potter...It is pretty overwhelming. To tell you the truth, you almost come off as a Southern Baptist Revival Preacher the way you rant and rave against the "Dragon." It is what got my attention, however, and I appreciate the quality of your work, but it is very overwhelming.
  • Again, thanks for being such a resource to potters over the years!
  • I have been studying your web site and which I have found extremely helpful for someone like me who is not a chemist!
  • I have thoroughly enjoyed the articles on your web site.

What people have said about Insight-Live

  • Insight live is great...!
  • I have everything hand written in my notes from my glaze void, but obviously, is not searchable. It's great what you've done.
  • Your site is amazing and your videos too. Such an inspiration.
  • Awesome program you have!
  • Thank you so much for this wonderful resource you have created! I have found all of the information in the Digital Fire database as well as Insight to be incredibly helpful tools in the ceramic world.
  • Learning ceramics has been a long process full of tests, frustration but at the end full satisfaction once we learn more every day... Thank you for your website, I use it for constant reference
  • I have been receiving your excellent emails for some time and frequent your site for good data. I wanted to thank you for all your work. It has proven helpful as a ceramics instructor at both the college level and the art center level.



https://digitalfire.com, All Rights Reserved
Privacy Policy

1