Method for Manufacturing Moulds for the Maputo Ceramic Stove

Tom Miles

Method for Manufacturing Moulds for the Maputo Ceramic Stove
Crispin Pemberton-Pigott, New DawnEngineering/ProBEC, February 18, 2007

Inner FormInner Form

This method is used to make the master mould, from which other sets of outer moulds can be made to create additional moulds at a high rate.

The nylon form shown in the series is actually the tool for holding the moulds when they are put into the Jigger to make the stove body.

The tool is used to make a perfect master mould, drying slowly for more than a week. Following this, other sets of outer moulds can be cast around the master mould. There can be many of them. Each outer mould can be used to make several moulds per day, at least two. In this way the number of moulds required for mass production can be made, each virtually identical to the original master mould.

It is expected that to make 10,000 stoves a month we will need something like 200 moulds, produced from 2 or 3 outer moulds. As demand rises, more moulds are produced to run through the Jigger.

Each mould can produce 2 or 3 stoves bodies per shift.

Regards
Crispin
Apply vaseline or greaseApply vaseline or grease
Outer Form - Apply VaselineOuter Form - Apply Vaseline
Place Inner Form into positionPlace Inner Form into position

Secure InnerForm with thumbwheelSecure InnerForm with thumbwheel

Mix Rhinocast or Almold 60Mix Rhinocast or Almold 60
Pour in the mixPour in the mix
Pour in more. . .Pour in more. . .
Top it offTop it off
Strike off the mix levelStrike off the mix level
Clean off the excessClean off the excess
Leave it to dryLeave it to dry
Remove the Inner FormRemove the Inner Form
Remove the Mould when it is dryRemove the Mould when it is dry
Dry it by the furnaceDry it by the furnace
Mount the mould holder on the jiggerMount the mould holder on the jigger
Formed stove after removingFormed stove after removing
Fuel grates made by the same methodFuel grates made by the same method
The jigger can produce different thicknessesThe jigger can produce different thicknesses