RECKLI MOLD WAX

RECKLI Mold Wax is a release agent that enables easy mold removal when producing models.

Does not affect the cure of RECKLI two-component materials
It also allows the separation of silicone from silicone

• Alçı, ağaç ve araldite modellerden kalıbın ayrılmasına yardımcı olur.
• RECKLI Mould Wax, model üretirken kolay kalıp sökmeyi sağlar
• Solvent-based
• High quality
• Fine-particle, hard wax
• Does not affect the cure of RECKLI two-component materials

RECKLI ELASTOMER A55

The Reckli Pur-Elastomer A55 is a two-component product that will help you achieving the best results. It is used for manufacturing flexible models, fittings, formliners and molds made out of gypsum, ensuring exact reproduction of surface contours and textures. Reckli A55 Pur-Elastomer A55 offers a fast set up, extended lifetime and 55 hardness degree. This product, which has been used safely in the ceramic industry for years, will be your biggest assistant in creating your gypsum molds  thanks to its flexibility and fast hardening feature. 

• Best in the market for traditional production
• Almost shrinkage-free
• Solvent free
• Thanks to its fast curing time, you get faster results
• Cold curable
• Available in 22.5 kg cans with hardener
• Sertleştikten sonra numune alınabilir veya rötuşlanabilir

RECKLI yazısı ilk önce Castimo üzerinde ortaya çıktı.

CASTIDUR is a highly effective cleaning agent for porous resin molds to remove residues of slip and lime and prevents formation of mildew. It is recommended to clean porous resin molds regularly to maintain efficiency and to achieve a long lifetime of the porous resin molds. During the lifespan of a porous resin mold, residues of slip, lime and other particles dry on the resin surface and lead to clogging of the pores. CASTIDUR is available in batches of 5, 10 and 25 kg and is ready for use with a concentration of 1-2%.

• Removes residues of slip
• Prevents mildew formation on mold
• Expands the lifespan of the mold
• Prevents lime formation in the mold
• Perfect cleaning product for high pressure porous resin molds

CASTIDUR yazısı ilk önce Castimo üzerinde ortaya çıktı.

HPSC Supply

Castimo supplies advanced High Pressure Slip Casting (HPSC) forming technique used to produce complex shapes with high precision and density. We support our customers to transform their operations into a modern, efficient, and future-ready systems. Additionally, we support all types of HPC machines, ensuring seamless integration and optimized performance for your ceramic manufacturing processes.

HPSC Consultancy

Castimo provides High Pressure Slip Casting (HPSC) consultancy services with expert guidance on process optimization, equipment configuration, mold design, slip formulation and production workflow. We focus on improving cycle times, enhancing product consistency, minimizing material waste and reducing operational costs. We help manufacturers achieve higher efficiency, improved quality control and sustained competitive advantage in HPSC operations.

High Pressure Casting Machines (HPSC) yazısı ilk önce Castimo üzerinde ortaya çıktı.

Plaster Model Molds

Plaster molds for slip casting are known for their high absorbency, allowing them to efficiently draw water from the ceramic slip. This process enables the clay to solidify evenly against the mold surface, ensuring accurate shapes and consistent casting quality.​

Araldite/Epoxy Case Molds

Araldite resin systems, combined with suitable hardeners, form rigid and heat-resistant molds for demanding industrial applications. They are commonly used to produce case molds (master molds), which serve as the reference molds for manufacturing working molds—typically plaster molds— in high-volume production.​

Porous Resin Molds

Castimo Ready Molds for High Pressure Casting (HPC) are produced from high-porosity porous resin, ensuring fast water drainage and efficient casting. Designed for complex shapes, they provide quick demolding, high repeatability, and long service life, making them ideal for sanitaryware, tableware, and technical ceramics.

Solid Resin Blocks

Our Solid Resin Blocks, used for manufacturing durable components and tooling parts that require high strength and chemical resistance, are engineered for exceptional durability, superior chemical resistance, and excellent dimensional stability. These properties make them ideal for high-performance applications in ceramic production and other industrial environments where precision and long-term reliability are essential.

Molds yazısı ilk önce Castimo üzerinde ortaya çıktı.

Porous Resin Molds for High Pressure casting provide a highly efficient solution for modern ceramic production. Compared to conventional slip casting, this technology enables significantly higher output, longer mold life, and lower production costs. 

Higher Output with Fewer Resources

Traditional casting methods usually allow only one to two products per shift per mold. High-pressure casting with porous resin enables 20 or more products per shift using a single mold, depending on mold design, machine setup, and slip properties. This results in shorter cycle times, reduced labor, and lower space requirements. 

Long-Lasting and Cost-Effective Mold Technology

Porous resin molds offer a much longer service life than conventional plaster molds. With optimized coordination of mold design, machine parameters, and slip formulation, over 100.000 casting cycles can be achieved. This makes porous resin an ideal choice for high-volume industrial production. 

High-Quality Porous Resin by Castimo

Castimo supplies high-quality porous resin systems with an excellent price–performance ratio. Customers benefit from reliable material quality, stable production results, and comprehensive technical support before and after sales. 

Flexible Resin Systems for Different Applications

Castimo offers four- and five-component Porous Resin systems, available in MICRO and PRO versions. Each system is carefully selected according to the application, mold size, and production requirements to ensure optimal performance in high-pressure casting processes.

The materials are easy to process and can be reliably cast into epoxy resin case molds, such as Araldite, or other suitable epoxy-based mold frames. This ensures safe handling, uniform material distribution, and consistent, reproducible mold quality.  

Quality Control and Technical Support

To guarantee consistent mold quality, Castimo works closely with customers to monitor critical production parameters. Quality control procedures and training programs support the correct manufacturing and use of porous resin molds. 

Continuous Innovation

With many years of industry experience, Castimo continuously improves its porous resin technology to set higher standards in efficiency, reliability, and ceramic production performance. 

• Small pores of 12-15 microns (Resin Micro)
• Large pores of 16-19 microns (Resin Pro)
• Customer-specific pore structure option
• Customer-specific product production

Defined pore structure with a mean pore radius of 12-15 (small pores) and a narrow arrangement of the pores (MICRO)

• This pore structure is specifically designed for fine parts of slip and reduces clogging (contamination) of pores.
• Minimal deformation in the pressure casting system due to its high resistance.
• Products will be shipped with 4 component system.
• Easy casting thanks to long processing time.
• Ensures long mold life.
• High pressure and abrasion resistance.

Working pressure

5-30 bar

Mean pore radius

12-15 micron

Porosity

25-30 %

Flexural strength

20-23 N /mm2

Compressive resistance

44-47 N /mm2

Flow rate

12-15 l/min

Shrinkage

approx. 0,2%

It has a medium/large pore structure along with a pore structure with a diameter of 16-19 microns

• Thanks to its medium/large pore structure, it allows you to get products 25% faster in the pressure casting system compared to Castimo Resin Micro.
• Minimal deformation in the pressure casting system due to its high resistance.
• Products will be delivered with 4 component system.
• Easy casting thanks to long processing time.
• Ensures long mold life.
• High pressure and abrasion resistance.

Working pressure

5-30 bar

Mean pore radius

16-19 micron

Porosity

25-30 %

Flexural strength

20-23 N /mm2

Compressive resistance

44-47 N /mm2

Flow rate

16-21 I/min

Shrinkage

approx. 0,2%

Porous Resin yazısı ilk önce Castimo üzerinde ortaya çıktı.

High pressure slip casting (HPSC or HPC)

HPC is a high-performance mass production system used to produce ceramic parts cost-efficiently with high density, strength, and dimensional accuracy. HPC systems are designed in case to produce sanitary ware, tableware and technical ceramics using high-pressure injection of clay slip (porcelain, stoneware, bone china, vitreous china (VC), fine fire clay (FFC)) into porous resin molds.

Porous resin molds are used in high-pressure casting because they allow for the easy release of the clay body after it has been cast. The porous surface of the resin mold allows air and water to escape during the casting process, preventing air pockets or other defects from forming in the final product. However, there are some limitations to using porous resin molds in high pressure casting. First, the porous surface can absorb some of the ceramic slurry, which can lead to variations in the density and strength of the final part. Second, the pores in the resin mold can become clogged over time, reducing the quality of the cast parts.

To overcome these limitations, it is important to choose a high-quality resin material as offered by Castimo that is resistant to absorption and clogging. It is also important to properly maintain and clean the molds to ensure consistent casting results.

Steps of High Pressure Slip Casting (Sanitary Ware)

The steps involved in high pressure slip casting are usually as follows:

• Mold preparation: The resin molds installed in the machinery must be clean and coated with a release agent to prevent the slip from sticking to the mold surface. An HPC machine uses water and air pressure to ensure that porous resin molds are cleaned between each cycle.
• Injection of the slip: The HPC machine will close the 2- or more part resin mold and the filling with slip starts. After pre-filling with slip pressure of 3 to 4 bars, the final slip pressure raises between 10 to 13 bars. The high pressure helps to overcome the resistance of the slip to flow into complex mold shapes and narrow features.
• Solidification: As the slip fills the mold, excess water is forced out through small pores in the porous resin mold surface, leaving behind a solid ceramic part with minimal shrinkage. The clay body formation process will be stopped when the required clay thickness is reached.
• Demolding: Once the clay body has solidified, the mold is opened and the clay body is carefully removed from the Porous Resin mold. In case of a common battery type HPC one person removes up to 12 molds all at once.
• Further treatment: The removed clay body may require additional processing steps to achieve the desired shape, surface finish, and mechanical properties, e.g.holes are being made, surplus material needs to be removed and surfaces are smoothed with a wet sponge.
• Pre-drying: The clay bodies will then dry until only a certain amount of water is left within.
• Burning: After pre-drying, the products are again checked for defects, glazed and burnt in the oven.
• Cleaning: The HPC mold cleans with water and air. Afterwards the mold closes again for the next casting process.

Overall High Pressure Slip Casting

On the whole high pressure casting with porous resin molds is a reliable and cost as well as time efficient method for producing high-quality ceramics. Due to the use of high-pressure and the level of automation, labor costs are reduced and production efficiency is increased.

High pressure slip casting is a manufacturing process used to produce ceramic parts with high density, strength, and dimensional accuracy. It involves injecting a ceramic slurry or “slip” into a mold at high pressure (typically ranging from 500 to 1500 psi) to fill the mold cavity and create a dense, uniform ceramic part.

The high pressure helps to overcome the resistance of the slip to flow into complex mold shapes and narrow features. As the slip fills the mold, excess water is forced out through small pores in the mold surface, leaving behind a solid ceramic part with minimal shrinkage.

The process is particularly suited for producing small to medium-sized parts with intricate shapes and fine details, such as ceramic dental prosthetics, electronic components, and precision mechanical parts. High pressure slip casting can also be used to produce larger parts, but this requires specialized equipment and may be more difficult to achieve uniform density and quality.

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High Pressure Slip Casting System (HPSC or HPC) yazısı ilk önce Castimo üzerinde ortaya çıktı.

Did you already know that porous resin is as well used for RAM Press process? With just the right know-how, porous resin molds are able to replace traditional plaster molds therefore being more accurate and more permanent. A porous resin mold ensures a long mold life and a high level of permeability to improve production processes

Process

In a RAM press machine, a ceramic body is shaped by pressing clay into molded shapes such as plates and bowls. The clay is placed between two halves of a mold (usually a male and a female). Then pressed into the required shape. Any imperfections of the surface can be cut away or removed with a wet sponge. Once a body is finished, it may then be decorated, glazed. And finally fired in the kiln.

The clay should be slightly stiff while still having water retention properties. That allows the body to form easily during the pressing cycle. The pressure that is required is subject to various conditions. Such as the thickness of the pressed piece. But usually falls fall within the range of 100 to 400 psi.

The molds that are being used are traditionally made of porous plaster/ gypsum cement embedded with porous tubes/air hoses. The pressed shape is instantly released by applying fluid pressure. Nowadays, more and more manufacturers realize the benefits being provided by porous resin molds compared to traditional plaster molds.

The process shown in operation in the series of photos and video below is semi-automatic requiring a minimum of manual operation.

Ram Press On Action – Castimo – YouTube

What can be produced with RAM Press

A RAM press can be used to produce complex shapes in a variety of sizes. Basically any shape that can be made in a two-piece mold can be used for Ram Press. Many companies in the ceramic fields are using the RAM process, this includes amongst others

• table ware
• sanitary ware
• oxide ceramics
• art ware
• electrical porcelain
• structural clay products

Appendages such as knobs and handles are applied directly on the formed body and holes may be punched simultaneously with the pressing process.

Advantages of RAM Press

Due to standardized production process and minimal manual operation, each piece of ceramic body is of uniform quality, thereby keeping the number of rejects from the forming to the kiln at a bare minimum. How much manual finishing is required after the ceramic body is removed from the press depends on the quality of the two halves of the mold.

With a RAM press an immediate increase in production can be achieved. Press cycle rates depend on a number of factors and with the present RAM pressing equipment 5 to 6 pressing cycles per minute can be achieved, with the average being 1,500 cycles in an eight-hour shift. Change over from one mold to another is done at the RAM press in a matter of minutes.

RAM Press molds

The RAM process mold life expectancy is very much dependent on the quality of the produced mold. The mold making process but also on the body type used, body consistency and dewatering required. Plaster mold life ranges usually from 1000 to 5000 pressings. Porous resin mold life expectation is considerably greater and can be reused during a significant time span, given that regular maintenance is being applied.

Porous resin RAM Press molds

As a result compared to traditional plaster molds, porous resin RAM Press molds are characterized by

• Considerably improved mold life expectation: less changing cycles due to exhausted molds
• Limited expansion of every RAM press product

Advantageous mechanical properties and required permeability to release excess water

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RAM Press – Get even better results with Porous Resin yazısı ilk önce Castimo üzerinde ortaya çıktı.

High Pressure Casting Process for Sanitary Ware

The casting process varies depending on the slip being used and the article being cast. In general, the following applies for casting of sanitary ware articles using High Pressure Casting technology.

Casting Process

• An already prepared Castimo Porous Resin is pre-filled with liquid clay body slip using a pressure of approx. 3 to 4 bars. Slip temperature should be between 35°C and 43°C.
• After the porous resin mold is filled with the right amount of slip, pressure is increased to approx. 10 to 13 bars.
• Porous Resin acts as a filter material. By applying pressure the water content of the liquid slip is released through the pores of the resin mold. And so solid clay forms on its inside surface. During this process, liquid slip starts to shape into a ceramic clay body.
• When dry, the solid clay body is removed from the porous resin mold. Any defects that show up are revised; i.e. holes and any excess material is being removed, then the surfaces are smoothed with a wet sponge.
• The articles are left for drying until the amount of water is further reduced (pre-drying)
• After pre-drying, the articles are again checked for defects and burnt in the oven.

It is recommended to clean porous resin molds regularly to maintain efficiency at the same time to achieve a long lifetime of the porous resin molds. During the lifespan of a porous resin mold, residues of slip, lime and other particles dry on the resin surface and lead to clogging of the pores. Without the right level of care, clogging of pores and mildew may significantly reduce the durability of a porous resin mold.Castimo offers with CASTIDUR a highly effective cleaning agent for porous resin molds to remove residues of slip and lime and prevents formation of mildew.

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High Pressure Casting 101 – The casting process for Sanitary Ware yazısı ilk önce Castimo üzerinde ortaya çıktı.

• Gypsum molds have a low toughness, can fracture easily and wear out quickly because the pores are eroded from the water that goes through them
• A large inventory of gypsum molds needs to be maintained to enable continuous production
• The production rate is lower due to longer casting cycles
• More production space is required to achieve the same outcome compared to high pressure casting
• Dimensional precision is lower due to differential shrinkage

Castimo Porous Resin revolutionizes the High Pressure Casting process.

High Pressure Casting advantages are:

• Extended mold lifetime
• Faster casting cycles and higher product outcome
• Even distribution of liquid slip
• High quality products – Smoother surfaces and improved body strength
• Lower operation & maintenance costs
• Easy demolding
• High accuracy with complex molds
• Opportunity of fully automated process

One porous resin mold can produce approximately 20,000 to 40,000 products however Castimo customers have often stated that with the right level of maintenance and care about 70,000 to 110,000 cycles can be achieved per mold. In addition, you usually finish up to two castings per hour. Compared to that plaster molds must be replaced every 90 to 130 cycles and a production cycle takes at least 8 hours or more.

Assuming that one article can be produced within 8 hours using traditional slip casting, whereas High Pressure Casting would be able to achieve in the same amount of time up to 16 articles, the gain of productivity and the return of investment is impressive. If large volumes of complex components are required, High Pressure Casting using Castimo Porous Resin molds will deliver with speed and precision.

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Check out our previous “Slip Casting – Put on the Pressure” article

https://www.castimo.de/slip-casting-put-on-the-pressure/

Traditional Slip Casting vs. High Pressure Casting yazısı ilk önce Castimo üzerinde ortaya çıktı.

• • • Traditional Slip Casting

Traditional slip casting uses plaster molds to allow this to happen. The water in the slip is drawn out into the walls of the plaster mold, leaving an inside layer of solid clay, which hardens over time. When dry, the solid clay can be removed and further processed. The process usually takes at least several hours per article.

It is a time-consuming process and the molds used for slip casting usually have a low toughness due to their high porosity. Plaster molds wear out rather quickly because the pores are eroded from the water that goes through them. Plaster molds must be replaced after every 90 to 130 production cycles.

• • • High Pressure (Slip) Casting

An alternative is to use porous resin molds instead. For that purpose, High Pressure (Slip) Casting (HPSC/ HPC), or simply Pressure Casting, has been developed as a high-performance production technology.

High Pressure Casting is used amongst others for producing sanitaryware, tableware, and technical or advanced ceramics. The slip is injected under high-pressure ) into porous resin molds and the  filtration through the pores of porous resin molds secures articles with adequate hardness, that are ready to be processed further.

Without compromising quality, geometries with considerable demands on function and design can be produced by using High Pressure Casting. The pressure injection even makes the particles bond more firmly resulting in smoother surfaces and improved body strength. The casting cycles for High Pressure Casting are extremely short when compared to the traditional slip casting method, as the cast forms in mere seconds. Also, porous resin molds can be reused for thousands of casting cycles if they are correctly maintained. This means as well that the process is extremely cost-effective when it comes to producing medium or large quantities. If large volumes of complex components are required, High Pressure Casting will deliver with speed and precision.

Nowadays, the number of companies producing High Pressure Casting machines and the numbers of companies using High Pressure Casting for their production process is increasing because of the benefits this technology offers for the ceramic industry. The flexibility and the cost-effectiveness is required to keep up with the competition.

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Slip Casting – Put on the Pressure yazısı ilk önce Castimo üzerinde ortaya çıktı.