Slip casting mold

A slip-casting mold comprising a plurality of mold portions forming a mold cavity when mated together, each mold portion comprising an air-tight housing, an intermediate layer of coarsely porous structure adjacent to the air-tight housing, a solid synthetic resin filter layer of fine open-cell structure, a slip supply duct connecting with said mold cavity and communicating with the outside of said air-tight housing, and a fluid flowing duct connected with said coarse intermediate layer and communicating with the outside of said air-tight housing, said resin filter layer penetrating into and permeably joined to the coarse intermediate layer and having a substantially precise shape and dimension defining a structure of substantially uniform fine open cells substantially free of emulsifier-based viscous substances, prepared according to a process comprising the steps of:

• bonding said intermediate layer of coarsely porous structure to said air-tight housing by force-filling a molding space defined between said air-tight housing and a model for said coarse intermediate layer with a mixture consisting essentially of aggregate particles and an adhesive synthetic resin material in an amount sufficient to partly bond said aggregate particles;
• forming said synthetic resin filter layer by casting a molding space defined between said coarse intermediate layer and a model for said resin filter layer having the shape of a desired slip-molded article, with a flowable emulsion material comprising by weight about 100 parts of a curable synthetic resin material, about 1 to about 30 parts of a non-ionic emulsifier, about 1 to about 200 parts of water, and about 50 to about 600 parts of filler particles;
• forming said resin filter layer structure of substantially uniform fine open cells by uniformly eluting said resin filter layer with a solvent to substantially remove the emulsifier-based substances from said resin filter layer;
• and
• further curing said resin filter layer.