Our unique moulds
PCL design, develop and manufacture a full range of moulds for the standard and technical ceramic industries
We have been making moulds for nearly 30 years!

PCL has manufactured an unprecedented number of single and multi-cavity pressure casting moulds during the last three decades to produce the full range of solid and drain cast products for sanitaryware, tableware and technical ceramics.

Our moulds are made from acrylic resin developed in house by PCL. We have a range of resins we can use to make the optimum mould.

PCL provides a full range of modelling, blocking and casing services in addition to manufacturing the moulds themselves.

All our moulds are test cast at PCL prior to shipment. Mould development programs are carried out on new products prior to general mould manufacture.

Moulding Technology and Manufacturing

Our blend of experience in ceramic production, materials technology and machine design and operation enables the full range of issues that are likely to face ceramic manufactures in the casting or forming of their products to be addressed.

 

PCL provides a full range of modelling, blocking and casing services in addition to manufacturing the moulds themselves.

With the recent introduction and upgrading of our 3D scanning, modelling and CNC systems we can develop and progress new and complex mould designs.

 

This has led to rapid prototyping and model development which has dramatically shortened the lead time in mould design and production. Design improvements and modifications can now easily be introduced onto existing designs.

PCL sanitaryware moulds have a proprietary internal air distribution matrix incorporated the structure of the mould material. This avoids the use of backplates. The avoidance of backplates allows more moulds to be fitted onto one machine, providing a significant increase in productivity.

Our moulds speak for themselves

On the left

 

Plaster moulds after 150 casts.

On the right

 

PCL Ceramics resin moulds after 40,000 casts (and still going).

 


Not only is the lifecycle dramatically greater, you will use less power, less water, and produce less waste, giving you a greener and more environmentally friendly operation.

Typically, a plaster mould has a life of around 80 casting cycles. PCL moulds are guaranteed for 20k cycles.

Plaster is soluble in water so after each cast a small amount of the mould is dissolved leading to loss of definition and features. The moulds need to be dried daily otherwise they become saturated and will not draw the water from the slip. The cost of mould drying is significant.

Plaster is inexpensive so the cost of a plaster mould is relatively low. But, due to the number of moulds used, the overall cost can be high, and the disposal of old moulds is a problem.

PCL's specialist moulds do not dissolve or erode over time, meaning the pieces made in your first cast are guaranteed to be as good as the pieces made in cast 20k. This also means no need for mounds of waste plaster.

We want to hear from you

Contact us for more information

Contact Details:
PCL Ceramics Ltd
Estuary Road
King's Lynn
Norfolk
PE30 2HS
United Kingdom

+44 (0) 1553 622000

©2020 by PCL Ceramics Ltd.