Manufacturing Processes

Top 6 terracotta tiling processes ranked by combined speed, scalability and cost. Each includes interactive flowcharts, parameter data, and detailed timing breakdowns.

#	Process	Forming Time	Startup Cost	Max Scale
1	Pressure Slip Casting	5–30 min	€3–10K	1.8m
2	Starch Consolidation	~90 min	~€0	Meter+
3	Agar Gelcasting	15–30 min	~€10	4m
4	LPCIM (Wax Injection)	0.5–5 min	€5–20K	~300mm
5	Geopolymer Casting	4–24h cure	~€500	Unlimited
6	Freeze-Drying	2–6h freeze + 24–72h sublime	€2–10K	Meter+

Pressure Slip Casting

Industry-proven. Fastest path to revenue, lowest tech risk.

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Key Parameters

Mold Types

PMMA via CNC (simple) or 3D print (complex) (10–40 bar, 10K–40K life)

Wall Buildup

15–30mm in 5–20 min (HPSC)

Drying

24–72h at 40°C, 70–80% RH

Firing

1000–1080°C, 14–24h cycle

Kiln

Electric shuttle, 1–2 m³

Process Flow

Timing Summary

Stage	Duration	Notes
Slip prep	Continuous	Amortized
PMMA mold (simple — CNC)	2–8h	One-time; 10K–40K life
PMMA mold (complex — 3D print)	4–12h	Binder-jet / Voxeljet
HPSC forming	5–20 min	Per piece at 10–40 bar
Finishing	10–30 min	Per piece
Drying	24–72h	Batch
Firing	14–24h	20–40 pcs/load
Total	~2–4 days

Reagents & Materials

Material	Role	Notes
Terracotta clay	Primary ceramic body	€50–150/t
Water	Slip medium	55–65 wt% solids
Dispersant	Rheology control	e.g. Dolapix CE-64
PMMA sheet / rod	Mold substrate for CNC or binder-jet printing
Glaze / engobe	Surface finish	Optional

Equipment

Machine	Role	Notes
Blunger / mixer	Slip preparation
Vacuum de-airer	Remove air bubbles from slip
CNC mill	PMMA mold fabrication (simple geometries)	⏱ 2–8h
Binder-jet 3D printer	PMMA mold fabrication (complex geometries)	e.g. Voxeljet; ⏱ 4–12h
HPSC machine	High-pressure slip casting at 10–40 bar
Drying oven / rack	Controlled drying at 40°C, 70–80% RH	24–72h
Electric shuttle kiln (1–2 m³)	Firing to 1000–1080°C	14–24h cycle

Starch Consolidation

Zero cost to trial. Silicone molds. Eliminates freeze-drying.

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Agar Gelcasting

Fastest gel (15 min). Zero waste — re-melt failures. Proven at 4m.

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LPCIM — Wax Injection

No water = no drying. Carousel 120 pcs/hr. Small items <300mm.

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Geopolymer Casting

No kiln. Room temp cure. Unlimited size. Cheapest energy.

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Freeze-Drying (Freeze Casting)

Rigid green body from freezer. Silicone molds. Best for porous/lightweight parts.

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Flexi-Mold Slip Casting (FMSC)

SLS-printed flexible TPU molds. No master/silicone step. Inherent porosity drives drying. Reusable 20+ cycles.

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Cross-Process Comparison

	Pressure Slip	Starch	Agar	LPCIM	Geopolymer	Freeze-Dry
Forming/pc	PMMA: 5–20m Plaster: 15–30m	90–120m	15–30m	0.5–5m	10–30m	2–6h freeze
Drying	24–72h	24–48h	24–72h	None	None	24–72h sublimation
Firing	14–24h	18–28h	16–26h	8–14h	None	14–24h
Total	2–5 days	3–4 days	2.5–4 days	1.5–2 days	1–28 days	4–6 days
Mold	PMMA or Plaster	Silicone	Silicone	Silicone	Silicone/HDPE	Silicone
Mold life	10K–40K / 50–150	20–100	20–100	100–500	20–50	20–100
Max size	1.8m	Meter+	4m	~300mm	Unlimited	Meter+
Startup	€3–10K	~€0	~€10	€5–20K	~€500	€2–10K
Reclaim?	Yes (slip)	Yes	Yes (re-melt)	Yes	No	Yes (re-slurry)
Toxicity	None	None	None	None	NaOH	None