Details
The plaster is not pure plaster of paris, but rather has additives to improve green strength, dry strength, permeability, and castability. For instance, talc or magnesium oxide are added to prevent cracking and reduce setting time; lime and cement limit expansion during baking; glass fibers increase strength; sand can be used as a filler. The ratio of ingredients is 70–80% gypsum and 20–30% additives.
The pattern is usually made from metal, however rubber molds may be used for complex geometry; these molds are called Rubber plaster molds. For example, if the casting includes reentrant angles or complex angular surfaces then the rubber is flexible enough to be removed, unlike metal. These molds are also inexpensive, reusable, more accurate than steel molds, fast to produce, and easy to change.
Typical tolerances are 0.1 mm (0.0039 in) for the first 50 mm (2.0 in) and 0.02 mm per additional centimeter (0.002 in per additional inch). A draft of 0.5 to 1 degree is required. Standard surface finishes that are attainable are 1.3 to 4 micrometres (50–125 μin).
Read more about this topic: Plaster Mold Casting
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