Model maker
One of the most important professions in the porcelain industry is the model maker. He/she is responsible for making the master mould of a porcelain item. The pattern setter ultimately decides on all the details that are included in a porcelain item. If a mistake is made in the pattern set-up, it will be reflected in all items that are ever produced from this master mould. Although the work of the pattern maker is often carried out by modellers, the modeller should not be confused with the pattern maker.
Modelling requires an experienced specialist. In 1823, modelling was declared a skilled occupation in Germany and was trained at many porcelain schools in Germany. In the meantime, model setters are referred to as a "former training occupation", as there is a lack of appropriate training centres and examination bodies. The specialised training for pattern setters has been integrated into the occupational profile of the industrial ceramist in the fields of pattern technology and process engineering.
Ceramic modellers make plaster or plastic moulds for the production of porcelain and earthenware objects. They mainly work with plaster, mix it with water and change the functional properties by adding binding agents. In preparation for their work, ceramic modellers provide the necessary documentation, for example work instructions, model drawings and the appropriate tools and materials. Ceramic modellers produce simple model drawings themselves. Depending on the shape and manufacturing process (turning, casting, pressing or die-casting) of the subsequent article, they use model drawings to produce simple master models from plaster, clay, plasticine and similar materials by turning, drawing and cutting.
They can also enlarge or reduce simple master models according to specifications and precisely calculate proportions and shrinkage in order to assign the item its final dimensions. More difficult model drawings and the corresponding master models are usually created by other specialists - for example ceramic modellers - and produced using the same processes. From this point onwards, the most important work of a ceramic modeller begins. By casting the master models, they produce master moulds as blasting, box or wedge moulds - regardless of their degree of difficulty.
They also master the production of master models and the enlargement and reduction of items. These models are used to produce the so-called master moulds, which can be duplicated as often as required to create working moulds. Ceramic modellers check the finished models and moulds for cracks and repair any defects. They make their own tools for cleaning, cutting and garnishing equipment. The care and maintenance of tools and equipment is a matter of course for them.
They set up working models (equipment) for testing and monitoring accuracy. This means that they produce working models or moulds by casting the master moulds with plaster or plastic. They prepare working moulds for series production by retouching and smoothing with sandpaper, sharpening the seams and coating the model surfaces with varnish to increase resistance. Working moulds can be produced as often as required. Ceramic modellers mainly carry out their work in workshops.
When producing casting moulds as master and working moulds, they prepare the working mass themselves from clay, modelling clay, plasticine, plaster and synthetic resins. For example, they mix plaster with water and binding agents to produce a working mould. They cast turning, casting, pressing or die-casting moulds from existing working models with the help of soft soap or shellac solution and model lubricant. To produce turning moulds, they operate the electrically operated turntable as well as the corresponding accessories such as modelling irons, modelling woods, turning irons, scraping irons, templates and the like. They use knives, blades, steel sheets, varnish and sandpaper, for example, to clean, smooth and consolidate the moulds.
The modeller works under extremely difficult physical conditions: Changing temperatures and changing humidity due to dryers, exposure to mineral dusts, chemical gases and vapours, wet work, direct contact with oils, greases, lubricants and plastics with the risk of allergisation, odour pollution and permanent standing at work.
Good, capable model setters are hand-picked worldwide and are sought after everywhere!