ClearlyClayton

This waste mold process also looks promising, similar to the patent you shared where the shell is painted on. There is an interesting extra step of having a delicate inner shell to protect the cast, and a more robust outer shell for structural support. https://youtu.be/t6d10ngvSYo

@PeterH NASA using algae as a release agent Man you are a genius with these links, thank you! This is a brilliant idea to paint a thin shell and then peel it off. I will be reading this patent in detail.

@PeterH That thread is brilliant thank you!! Like @tkw954 I was intending to 3D print the master, but using a wax-based low temperature filament. However using water- or acid-soluble filament sounds better, and could hopefully leave minimal contamination. The master would be a roughly 30cm tall full human figure with limbs and potentially separate fingers (the worst possible for casting essentially). I aim to get only 80% of the way with casting, cracks and damage are okay because I intend to thoroughly rework with more clay by hand. Also, I plan to use a wire armature, which means the mold will need to be at least two parts, but that's a separate challenge.. In the interest of keeping the clay workable, I don't want to subject it to any heat, so I'm considering adding sawdust or structural weakness to the plaster to assist in removal.

Hi all, I have an unusual case where I need to only do a single slip cast, of a full figure with lots of unavoidable undercuts. I plan to create the mold using a lost wax process. I don't plan on preserving the mold after casting. My question is how difficult it will be to break and remove the plaster from the clay once the slip has set, and if you have any tips for achieving a weaker plaster mix to make things easier. Thanks!!