Plaster Mould Making

Instructions:

For this part of the project, you will make a plaster mould of your prototype. With the resulting mould you will then be able to make clay copies of your design.

Rubric:

4pts Prototype - Take a picture of your spray-painted prototype.

4pts Mould - Take a picture of your finished plaster mould after it has been freed of the flashing and prototype.

2pts Documentation - Post your images on your website with the title "Plaster Mould"

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10pts Total

Materials / Tools

Materials:

3D Printed Prototype
Duct Tape
Water
Plaster
Paper Towles

Tools:

Duct Tape
Metal Tray
Metal Flashing
Pitchers
Digital Scale

Step 1. Spray Paint

Coat your prototype in Spray Paint.

Please make three (3) coats.

Allow the paint to DRY in-between coats.

Step 2. Tape Seam

Use the metal flashing around your prototype to create a metal tube. Make this seam WATERTIGHT.

There should be little or no gaps or spaces around your prototype!

Step 3. Tape Base

Use the duct tape to tape the flashing to the metal tray. Use short pieces. Press down on the tape to SEAL. MUST BE WATER TIGHT!

Use small 1 inch strips to get tight coverage.

PRESS DOWN on the tape for good adhesion.

Step 4. STOP

You must have your work CHECKED by the teacher before you to go to the next step!

Step 5. Mixing

Warning This Step MUST BE DONE AT THE BEGINNING OF THE PERIOD!

Using the scale...

Measure 400 grams of cool water in your container.
Add 600 grams of plaster to your bucket. Sprinkle in the plaster to break up the clumps
Mix using your hands BELOW THE SURFACE (we DONT want any bubbles in our slurry). Breakup all the clumps.

Place pitcher on scale.

Press the tear (zero out) button.

Add 400 grams of water.

Sprinkle in 600 grams of plaster.

Mix and break up clumps. DO NOT ADD BUBBLES!

Step 6. Pouring

Pour the plaster into the flashing cylinder SLOWLY and onto the back of a flat surface. This will help break up any bubbles. Use the back of your fingers to "jiggle" to top surface to dislodge bubbles from the slurry.

Pour plaster slurry on flat surface to break bubbles.

Jiggle top surface to free bubbles.

Step 7. Leaks

Drop a small handful of dry plaster onto any leaks IMMEDIATELY!

There is a LEAK!

Drop some dry plaster to top the leak.

Step 8. CLEAN EVERYTHING!

Plaster hardens into rock VERY QUICKLY and is difficult to remove.

Wipeout excess plaster with a paper towel and throw it away.
Use sink and sponge to clean the THIN FILM that remains.

Wipe off as much plaster as possible.

Your pitcher should be AT LEAST this clean before going to the sink.

Use the green scouring pad to clean the residue off the pitcher.

Step 9. Dry

Wait 1 full day for the plaster to SET. The following day you will....

Remove the duct tape (throw out)
Clean the flashing and return to cabinet
Remove your prototype from the mould
Place your plaster mould on the vent. The plaster is set but we need to evaporate ALL the water before we continue.

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