BACKGROUND ART Specifically, prior art ceramic casting utilizes one piece or multi-piece plaster molds, where ceramic material is cast by means of either slip-casting or press-out forming. For example, in reproducing a bust that includes undercuts (nostrils, ears, drapery folds, etc. ), a complicated time-consuming short lived and costly multi-piece plaster mold is utilized. The purpose of using a plaster mold is that it is highly absorbent like a sponge and it causes the ceramic material coming in contact with the plaster mold to lose its excess water, thereby making the ceramic casting rigid enough to be removed from the mold. One of the disadvantages in utilizing plaster molds is that extensive retouching of the ceramic casting involves labor intensive and time- consuming toil that is required to chaise out (remove) innumerable raised seams on the casting surface inherent in the plaster piece mold/casting process where mold sections meet. For undercutting situations, the separate plaster pieces must be made in a complex way to be disassembled so as to not cause distortion to or damage of the ceramic cast. Another disadvantage with plaster piece molds is that they are generally retired after a mere 12-20 ceramic casts have been generated from them due to the degradation of the plaster mold.

It is desirable to provide a new and improved ceramic casting process that utilizes flexible rubber molds for making ceramic casts.

DISCLOSURE OF THE INVENTION The present invention is a new and improved ceramic casting process that utilizes flexible rubber molds for manufacturing ceramic casts.

The casting process enables a ceramist to produce or form and then remove ceramic slip casts, ceramic press-out casts or ceramic spray casts from a flexible rubber mold. The process allows the ceramist to press-out cast, slip cast, or spray cast a variety of ceramic formulations into a flexible rubber mold in a general or specific manner to achieve a variety of results.

The casting process comprising the following steps: (a) providing a flexible rubber mold having a pattern of an object to be cast; (b) mixing a ceramic material in its powder state with a binder material which can be wet or dry; (c) adding water to the ceramic material to form a creamy ceramic mixture; (d) applying the creamy ceramic mixture onto the casting surface of the flexible rubber mold; (e) applying dampening means to the creamy ceramic mixture to prevent the creamy ceramic material from drying out; (f) non-frost freezing the creamy ceramic mixture contained within the flexible rubber mold in order to harden the creamy ceramic mixture to form the ceramic cast; (g) peeling off the flexible rubber mold from the hardened ceramic cast; (h) non-frost freezing the hardened ceramic cast to further remove additional moisture from the ceramic cast; (i) placing the hardened ceramic cast within a vacuum chamber ; (j) placing the vacuum chamber in a non-frost freezer so that the vacuum chamber removes any final moisture from the hardened ceramic cast; (k) pumping out the moisture from the hardened ceramic cast in the vacuum chamber; and (1) heat treating the hardened ceramic cast so that it becomes a permanent ceramic material.

Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.

BRIEF DESCRIPTION OF DRAWINGS Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated: FIG. 1 is a block diagram of a preferred embodiment of the present invention ceramic casting process; and FIG. 2 is a block diagram of an alterative embodiment of the present invention ceramic casting process.

MODES FOR CARRYING OUT THE INVENTION Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.

Described briefly, the present invention is a casting process that enables a ceramist to produce or form and then remove ceramic slip, spray or press-out casts from a flexible rubber mold. The process allows the ceramist to press-out or slip cast a variety of ceramic formulations into a flexible rubber mold in a general or specific manner to achieve a variety of results. This process also allows the ceramist to produce hollow casts as well as solid casts. These ceramic casts are then caused to dry out and are subsequently heat-treated (fired), thereby becoming a permanent ceramic cast in an electric, gas or wood kiln by conventional means.

The term"pattern"in terms of this invention is used as a pattern in the mold having either a plane surface, raised surface or decorative surface that might have undercuts.

It is noted that"slip"is a state of the art liquid ceramic material that is made pourable similar in state to a pancake batter. It is further noted that a"press-out"is a state of the art process whereby a ceramist presses ceramic material that is in a malleable or plastic state into a mold. It is also noted that"spray"casting is a state of the art process whereby ceramic material is pressure forced through a nozzle and onto the mold surface. It is further noted that in most cases a flexible rubber mold has a rigid outer support mold frequently known as a"mother mold"that causes the flexible rubber mold to maintain a specific shape.

Referring to Figure 1, there is illustrated diagrammatically the present invention process for manufacturing ceramic casts that utilize flexible rubber molds.

In this embodiment, the present invention process produces one color clay casts that are pressed-out.

The following steps are in accordance with the present invention process to produce a one color clay cast that is pressed-out.

In the first step of the present invention process and prior to casting, the desired ceramic material is mixed while it is in a powdered state with a binder material such as a water soluble wax or a water soluble polymer. The binder material is necessary to prevent the ceramic material from producing surface crazing and deformations due to the ceramic casting placement within a frozen environment.

Once the binder material is added, water is then added to produce a consistency of a creamy ceramic mixture. The ceramic material may be any type of water-based ceramic material such as earthenware clay body, stoneware clay body, porcelain clay body, etc. If the binder material is already in a liquid state, it can be directly added to the water and mixed with the dry ceramic material thereby producing the consistency desired. The binder material can be wet or dry.

In the second step of the process, an open-faced flexible rubber mold is provided, where the moist creamy ceramic mixture is taken a little at a time and is squeegeed with an applicator tool, finger or other suitable means onto the casting surface of the flexible rubber mold. The creamy ceramic mixture is carefully squeegeed in order to displace any entrapped air and all voids that would thereby cause a visually inferior cast that would therefore require undesirable retouching.

After the initial creamy ceramic mixture is squeegeed over a controlled area of approximately three to six inches square, the ceramist then continues to press the creamy ceramic mixture on top of the already applied creamy ceramic mixture within the flexible rubber mold. The ceramist carefully selects and inputs the desired colored binder-filler ceramic material into the specific desired locations. This layer of ceramic mixture is built-up to the desired thickness of anywhere from approximately 3/16 of an inch to 3/4 of an inch. This thickness will vary depending upon the size and desired thickness of the final ceramic cast.

In the third step of the process, the ceramist covers the applied creamy ceramic mixture with dampening cloths or dampening paper towels for maintaining dampness in order to prevent it from drying out or stiffening. A plant mister device or suitable means can also be utilized for dampening the creamy ceramic mixture.

In the fourth step of the process, the entire remaining casting surface of the flexible rubber mold is completely covered or filled with the creamy ceramic mixture.

In the fifth step of the process, if the object that has been molded is"in the round"rather than being an open-faced mold"relief', then it will be necessary to join the ceramic material that is cast upon the molded sections so that both or all parts of the ceramic cast may be permanently joined or fused becoming a monolithic casting.

This is done in the conventional manner known in the art as sculpture as"scoring"the contacted ceramic material areas with a knife or similar instrument to an average depth of approximately 1/4 inch.

In the sixth step of the process, after all the required areas are scored, then the ceramic slip is placed onto and into the"scored"areas and the mold sections are then closed.

In the seventh step of the process, the flexible rubber mold (with the creamy ceramic material already having been formed within it) is placed into a non-frost freezer in order to temporally rigidify the creamy ceramic mixture. This non-frost freezer environment will also aid in moisture desiccation. After adequate time (generally an hour or more depending on the mold's design) has elapsed, and the creamy ceramic mixture has become sufficiently hard, the flexible mold is removed from the non-frost freezer environment. Acting as quickly as possible, the mold is then disassembled, where the rubber mold is peeled off from the hardened ceramic cast before the ceramic material has a chance to defrost to any degree. During de- molding, if the ceramist notices any defrosting of the ceramic cast while still within the mold, it should be placed back into the non-frost freezer to re-harden the ceramic cast. Once the ceramic material is rehardened, any remaining mold sections may be removed. It is noted that should a non-frost freezer room be used to freeze the castings while within the molds, then the above defrosting concern will not be applicable.

In the eighth step of the process, once the ceramic casting has been removed from the flexible rubber mold, the cast can then be set back into the non-frost freezer, if desired, so that additional moisture can be removed from the ceramic material by means of desiccation. Total desiccation can be achieved within a non-frost freezer environment. Alternatively, total desiccation can be achieved by means of placing the ceramic cast within a vacuum chamber and thereafter placing the vacuum chamber in the freezer. The vacuum will remove any final moisture from the ceramic cast. Where necessary, props or pillows can be used to support the ceramic cast while it desiccates. In order to accomplish this thorough type of vacuum desiccation, it is necessary to use a vacuum pump or adaptable compressor capable of producing a vacuum between 29 inches of Mercury and 29.888 inches of Mercury. The benefit of vacuum desiccation and/or non-frost freezer dessication of the ceramic cast is that the casting while in its frozen state, remains rigid and will not distort as can happen when the cast is brought to a more ambient room temperature and air drying occurs. In this ambient room temperature state warping, collapsing, and cracking are omnipresent concerns.

In the ninth step of the process, while the ceramic material is in a leather hard state, any retouching can be done to the raised seams and to any imperfections that may have occurred during the entire casting process. Once the ceramic cast has been thoroughly dried out it can be heat-treated (fired) in an electric, gas or wood heated kiln to become a permanent ceramic material by conventional means.

The following steps are in accordance with the present invention process to produce two or more color clay cast that are pressed-out.

In the first step of the present invention process, prior to casting, the desired ceramic material is mixed while it is in a powdered state with a binder material such as a water soluble wax or water soluble polymer. The binder material is necessary to ultimately prevent the ceramic material from producing surface crazing and deformations due to the ceramic cast's placement within a frozen environment. Once the binder material is added, water is then added to produce a consistency of a creamy ceramic mixture. The ceramic material may be any type of water-based ceramic material such as earthenware clay body, stoneware clay body, porcelain clay body, etc. If the binder material is already in a liquid state, it can be directly added to the water and thereupon mixed with the dry ceramic material, thereby producing the consistency desired. The binder material can be wet or dry.

In the second step of the process, the creamy ceramic mixture is taken a little at a time and is squeegeed with an applicator tool, finger or other suitable mean onto the molding surface of the flexible rubber mold. After the initial creamy ceramic mixture is squeegeed into all the desired voids, (where a first color ceramic material such as"white"ceramic material is desired) the ceramist removes any excess clay by scraping it away with a rigid scraper. It is noted that if desired that more than one color of ceramic material can be placed in specific raised areas in the flexible rubber mold, these raised areas would be seen as indented voids in the negative flexible mold. The ceramist carefully selects and inputs the desired colored binder-filled ceramic material into these specific desired locations.

In the third step of the process, once all the major excess ceramic material has been scraped away from the undesired areas, the ceramist lightly mists the background surface of the flexible rubber mold with water. The ceramist then takes a fine water-wet brush and wets-out (loosens) the residual undesired ceramic material by means of wet brushing. Dampening paper towel or suitable means is laid over the misted surface and a dry brush is passed over the paper material causing the loosened undesired ceramic material to be absorbed into the applied absorbent paper towel by means of capillary action. The process should be repeated until the background surface of the flexible rubber mold is completely free of any unwanted residual ceramic material causing an unwanted haze or marbleizing to appear on the back-up second color ceramic such as"blue"ceramic material.

In the fourth step of the process, once the mold has been completely cleaned of all undesired"white"ceramic material, the back-up"blue"ceramic material should be applied or squeegeed onto the"white"ceramic material and all exposed casting surfaces of the flexible rubber mold. Care should be taken so that when the ceramist squeegees the"blue"ceramic material onto the"white"ceramic material, none of the "white"ceramic material is disturbed and dragged out of its negative mold voids causing it to mix with the"blue"ceramic material causing an undesired haze or marbleizing. It is noted that an alternative method of forming the"blue"ceramic material background into the mold is to pour, spray or lay in slip into the mold.

In the fifth step of the process, the"blue"ceramic material should continue to be built-up to its desired thickness.

In the sixth step of the process, the flexible mold (with the creamy ceramic material already having been formed within it) is placed into a non-frost freezer in order to temporally rigidify the creamy ceramic mixture. This non-frost freezer environment will also aid in moisture desiccation. After adequate time has elapsed, (generally an hour or more depending on the mold's design) and the creamy ceramic mixture has become sufficiently hard, the mold is removed from the non-frost freezer.

Acting as quickly as possible, the mold is then disassembled, where the flexible rubber mold is peeled off from the hardened ceramic cast before the ceramic material has a chance to defrost to any degree. During de-molding, if the ceramist notices any defrosting of the ceramic cast while still within the mold, it should be placed back into the non-frost freezer to re-harden the ceramic cast. Once hard, any remaining mold sections may be removed. It is noted that if a non-frost freezer room is used to freeze the castings while within the molds, then the above defrosting concern will not be applicable.

In the seventh step of the process, once the ceramic casting has been removed from the flexible rubber mold, the cast can then be set back into the non-frost freezer, if desired, so that additional moisture can be removed from the ceramic material by means of desiccation. Total desiccation can be achieved within a non-frost freezer environment. Alternatively, total desiccation can be achieved by means of placing the ceramic cast within a vacuum chamber which is in turned is placed within a non- frost freezer. The vacuum removes any final moisture from the ceramic cast. Where necessary, props or pillows can be used to support the ceramic cast while it desiccates. In order to accomplish this thorough type of vacuum desiccation it is necessary to use a vacuum pump or adaptable compressor capable of producing a vacuum between 29 inches of Mercury and 29. 888 inches of Mercury. The benefit of vacuum desiccation or non-frost freezing dessication of the ceramic cast is that the cast while in its frozen state, remains rigid and will not distort as can happen when the cast is brought to a more ambient room temperature and air drying occurs. In this ambient room temperature state, warping and cracking are omnipresent concerns.

In the eighth step of the process, while the ceramic material is in a leather hard state, any retouching can be done to the raised seams and to any imperfections that may have occurred during the entire process. Once the ceramic cast has thoroughly dried out, it can be heat-treated (fired) in an electric, gas or wood heated kiln to become a permanent ceramic material.

The following steps are in accordance with the present invention process to produce a one-color casting that is cast by means of slip casting.

In the first step of the present invention process, prior to casting, the desired ceramic material is mixed while in a powdered state with a binder material such as water soluble wax or water soluble polymer. The binder material is necessary to prevent the ceramic material from producing surface crazing and deformations due to the ceramic casting placement within a frozen environment. The ceramic material may be any type of water-based ceramic material including earthenware clay body, stoneware clay body, and porcelain clay body. It is noted that if the binder material is already in a liquid state, it can be directly added to the water and mixed with the dry ceramic material thereby producing the consistency desired. The binder material can be wet or dry. A small amount of surfactant can be added to the ceramic formula in order to prevent fish-eyeing of the slip brush coat when it comes in contact with the flexible rubber mold. This surfactant can be mixed with the water and then mixed with the ceramic powder to produce a slip consistency.

In the second step of the process, the ceramic slip is applied to the casting surface of the flexible rubber mold with a brush until all desired surfaces are covered.

Any air bubbles are removed. A ceramic spray gun can also be used to apply the ceramic slip. The ceramist carefully selects and inputs the desired colored binder- filler ceramic material into the specific desired locations.

In the third step of the process, if the flexible rubber mold is a multi-section type, the ceramic slip can be applied along and just over the parting lines of the flexible mold's casting surface. This area can be described as the contact surface where adjoining sections of the mold meet. This is important since all seamed areas of the cast to be joined with the ceramic slip will need to create a monolithic cast surface when the mold is closed. By applying ceramic slip just past the casting surface onto the mechanical joining surface, the ceramist insures a continuous surface of the casing when the mold sections are closed. A multi-pieced mold is closed at this time. If the mold is a one-piece open-faced mold, the ceramic slip should not be applied beyond the casting surface and the ceramist should proceed as follows. The mold is placed into a non-frost freezer in order to rigidify the ceramic material. After adequate time has elapsed, (generally an hour or more depending on the mold's design) whereby the ceramic material has become sufficiently rigid, the ceramist pours into the mold void sufficient additional ceramic slip to entirely cover over the already brushed on or sprayed-on ceramic slip with a second slushed-on coating of ceramic slip. Any excess ceramic slip is poured out of the mold.

In the fourth step of the process, the mold is placed back inside the non-frost freezer. The ceramic slip is allowed to chill inside the non-frost freezer until it has reached a consistency whereby it will not flow.

In the fifth step of the process, additional layers of ceramic slip are added in the above manner until the desired thickness is achieved.

In the sixth step of the process, once the ceramic material has been cast into the mold, the mold and the ceramic material within it are placed into a non-frost freezer in order to rigidify the ceramic material. The non-frost freezer will aid in moisture desiccation. After adequate time has elapsed, (generally an hour or more depending on the mold's design) whereby the ceramic material has become sufficiently hard, the mold is removed from the non-frost freezer. Acting as quickly as possible, the mold is then disassembled. The flexible rubber mold is peeled off from the ceramic cast before the ceramic material has a chance to defrost to any degree. During de-molding, if the ceramist notices any defrosting of the ceramic cast while still within the mold, it can be placed back into the non-frost freezer to re- harden the ceramic cast. Once hard, any remaining mold sections may be removed.

It is noted that if a non-frost freezer room is used to freeze the cast while within the molds, then the above defrosting concern will not be applicable.

In the seventh step of the process, once the ceramic cast has been removed from the flexible rubber mold, the cast can then be set back into the non-frost freezer, if desired, so that additional moisture can be removed from the ceramic material by means of desiccation. Total desiccation can be achieved within a non-frost freezer environment. Alternatively, total desiccation can be achieved by means of placing the ceramic cast within a vacuum chamber. The vacuum will remove any final moisture from the cast. Where necessary, props or pillows can be used to support the casting while it desiccates. In order to accomplish this thorough type of vacuum desiccation, it is necessary to use a vacuum pump or adaptable compressor capable of producing a vacuum between 29 inches of Mercury and 29.888 inches of Mercury.

The benefit of vacuum or non-frost freezer desiccation of the ceramic cast is that the cast while in its frozen state remains rigid and will not distort as can happen when the casting is brought to a more ambient room temperature and air drying occurs. In an ambient room temperature state, warping and cracking are omnipresent concerns.

In the eighth step of the process, while the ceramic material is in a leather hard state, any retouching can be done to the raised seams and to any imperfections that may have occurred during the entire casting process. Once the ceramic cast has thoroughly dried out it can be heat-treated (fired) in an electric, gas or wood heated kiln to become a permanent ceramic material.

Referring to Figure 2, the following steps are in accordance with the present invention process to produce one color clay casts that are pressed-out and subsequently desiccated with desiccating gel (sand).

In the first step of the present invention process and prior to casting, the desired ceramic material is mixed with water to produce a consistency of a creamy or stiff ceramic mixture. The ceramic material may be any type of water-based ceramic material such as earthenware clay body, stoneware clay body, porcelain clay body, etc.

In the second step of the process, an open-faced flexible rubber mold is provided, where the creamy or stiff ceramic mixture is taken a little at a time and is squeegeed with an applicator tool, finger or suitable means onto the casting surface of the flexible rubber mold. The creamy or stiff ceramic mixture is carefully squeegeed in order to displace any entrapped air in any and all voids. After the initial ceramic mixture is squeegeed over a controlled area of approximately three to six inches square, the ceramist then continues applying the creamy or stiff ceramic mixture on top of the already applied creamy or stiff ceramic mixture. This layer of ceramic mixture is built-up to the desired thickness of anywhere from approximately 3/16 of an inch to 3/4 of an inch. This thickness will vary depending upon the size and desired thickness of the final cast.

In the third step of the process, the ceramist covers the applied creamy or stiff ceramic mixture with damp cloths or paper towels in order to prevent if from drying out. Alternatively, a plant mister device can be used to wet the creamy ceramic mixture.

In the fourth step of the process, the process is continued until the casting surface of the entire flexible rubber mold (one, both or all cast sides as applicable) is completely covered with the creamy ceramic mixture.

In the fifth step of the process, if the object that has been molded, is"in the round"rather than being an open face molded"relief'then it will be necessary to join the creamy or stiff ceramic mixture that is within the mold sections so that both or all parts of the ceramic cast may be permanently joined or fused. This process is completed by conventional means known in the art of sculpture as"scoring"the contacting clay areas with a knife or similar instrument to an average depth of about one quarter inch.

In the sixth step of the process, after all required areas are scored then slip is placed onto the scored area and the mold is then closed.

In the seventh step of the process, once the mold is closed, the ceramist pours a desiccating gel into the mold void. This gel (having the consistence of a fine grained sand) is left in the mold void until such time as the ceramic cast has sufficiently dried out so that it can be removed from the mold without distortion. If the desiccating gel become super-saturated such that it is incapable of absorbing any more moisture, the ceramist pours out the desiccating gel from the mold. The ceramist then refills the mold with fresh desiccating gel until the ceramic material becomes sufficiently rigid to remove from the mold.

In the eighth step of the process, while the ceramic material is in a leather hard state, any retouching can be done to the seams and to any imperfections that may have occurred during the entire casting process. Once the ceramic cast has thoroughly dried out it can be heat-treated (fired) typically in an electric, gas or wood heated kiln to become a permanent ceramic material.

Defined in detail, the present invention is a process for manufacturing a one color ceramic cast that is pressed-out utilizing a flexible rubber mold, the process comprising the steps of : (a) providing the flexible rubber mold having a pattern of an object to be cast; (b) mixing a ceramic material in its powder state with a binder material to prevent the ceramic material from producing surface crazing and deformations; (c) adding water to the ceramic material to form a consistency of a creamy ceramic mixture; (d) applying the creamy ceramic mixture onto a casting surface of the rubber mold such that any entrapped air in the casting surface is removed, where the creamy ceramic mixture is built-up to a desired thickness; (e) applying dampening means to the creamy ceramic mixture to prevent the creamy ceramic mixture from drying out; (f) non-frost freezing the rubber mold with the creamy ceramic mixture contained therein in order to harden and remove moisture from the creamy ceramic mixture to form the ceramic cast; (g) peeling off the rubber mold from the hardened ceramic cast before the creamy ceramic mixture has a chance to defrost; (h) non-frost freezing the hardened ceramic cast to further remove additional moisture from the ceramic cast; and (i) heat treating the hardened ceramic cast so that it becomes a permanent ceramic material.

Defined alternatively in detail, the present invention is a process for manufacturing at least two color ceramic cast that is pressed-out utilizing a flexible rubber mold, the process comprising the steps of : (a) providing the flexible rubber mold having a pattern of an object to be cast; (b) mixing a first color ceramic material in its powder state with a binder material to prevent the first color ceramic material from producing surface crazing and deformations; (c) mixing a second color ceramic material in its powder state with the binder material to prevent the second ceramic material from producing surface crazing and deformations; (d) adding water to the first ceramic material to form a consistency of a first creamy ceramic mixture; (e) adding water to the second ceramic material to form a consistency of a second creamy ceramic mixture; (f) applying the first creamy ceramic mixture into desired void locations of the rubber mold; (g) scraping off any excess undesired ceramic material from the mold surface; (h) misting the rubber mold casting surfaces; (i) applying absorbent means to the mold casting surfaces with said rubber mold for removing loose ceramic material; (j) applying the second creamy ceramic mixture onto top of the first creamy ceramic mixture within the rubber mold; (k) non-frost freezing the rubber mold and the creamy ceramic mixtures contained therein order to harden and remove moisture from the first and second creamy ceramic mixtures to form the ceramic cast; (1) peeling off the rubber mold from the hardened ceramic cast before the first and second creamy ceramic mixtures have a change to defrost; (m) non-frost freezing the hardened ceramic cast to remove remaining moisture from the ceramic material; and (n) heat treating the hardened ceramic cast so that it becomes a permanent ceramic material.

Defined also alternatively in detail, the present invention is a process for manufacturing a one color ceramic cast that is slip cast utilizing a flexible rubber mold, the process comprising the steps of : (a) providing the flexible rubber mold having a pattern of an object to be cast; (b) mixing a ceramic material in its powder state with a binder material to prevent the ceramic material from producing surface crazing and deformations; (c) adding water to the ceramic material to form a consistency of a creamy ceramic mixture; (d) adding surfactant to the creamy ceramic mixture to form a slip consistency in order to prevent fish-eyeing of the slip consistency when it comes in contact with the rubber mold; (e) applying the slip consistency to the casting surface of the rubber mold; (f) non-frost freezing the rubber mold and the slip within the rubber mold; (g) removing the rubber mold from said non-frost freezing and applying additional slip into void of the rubber mold; (h) non- frost freezing the rubber mold and the slip within so that the slip does not flow ; (i) further applying additional layers of the slip consistency until a desired thickness is produced ; (j) non-frost freezing the rubber mold with the slip within in order to harden the ceramic cast; (k) peeling off the rubber mold from the hardened ceramic cast before the slip has a chance to defrost; (1) non-frost freezing the hardened ceramic cast to further remove remaining moisture from the slip casting; and (m) heat treating the hardened ceramic cast so that it becomes a permanent ceramic material.

Defined further alternatively in detail, the present invention is a process of manufacturing a one color ceramic cast that is pressed-out utilizing a flexible rubber mold, the process comprising the steps of : (a) providing the flexible rubber mold having a pattern of an object to be cast; (b) mixing a ceramic material in its powder state with water to form a consistency of a creamy ceramic mixture; (c) applying the creamy ceramic mixture onto a casting surface of the flexible rubber mold; (d) further pressing the creamy ceramic mixture into the flexible rubber mold until a desired thickness is produced; (e) applying dampening means to the creamy ceramic mixture in order to prevent it from drying out; (f) scoring the contacting areas of the creamy ceramic mixture; (g) placing slip into the scored contacting areas with the creamy ceramic mixture; (h) closing the flexible rubber mold; (i) pouring a desiccating gel onto the flexible rubber mold to dry out the creamy ceramic mixture to form the ceramic cast so that it can be removed from the flexible rubber mold without distortion; and (j) heat treating the ceramic cast so that it becomes permanent ceramic material.

Further defined broadly, the present invention is a process for manufacturing a ceramic cast from a flexible mold, the process comprising the steps of : (a) providing the flexible mold having a pattern of an object to be cast; (b) mixing a ceramic material with a binder material; (c) adding water to the ceramic material to form a creamy ceramic mixture; (d) applying the creamy ceramic mixture onto a casting surface of the flexible mold such that the creamy ceramic mixture is built-up to a desired thickness; (e) drying the creamy ceramic mixture within the flexible mold; (f) peeling off the flexible mold from the dry ceramic cast; and (g) heat treating the ceramic cast so that it becomes a permanent ceramic material.

Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.

The present invention has been described in considerable detail in order to comply with the patent laws by providing full public disclosure of at least one of its forms. However, such detailed description is not intended in any way to limit the broad features or principles of the present invention, or the scope of the patent to be granted. Therefore, the invention is to be limited only by the scope of the appended claims.