Introduction:
In the early stages of sanitaryware development, many manufacturers focus solely on visual dimensions. At Sunlets, our philosophy is different: a sample must be the physical manifestation of the process window. By evaluating slurry rheology, green body microstructure, and firing kinetics, we ensure every sample carries the "DNA" for stable mass production.
The performance of the Casting Slip dictates the efficiency of High-Pressure Casting (HPC).
Thixotropy & Yield Stress: We utilize precision rotational viscometers to assess slurry behavior under varying shear rates.
Original Insight: Ideal HPC slurries must exhibit specific shear-thinning properties. According to , adjusting the Deflocculant to increase the yield stress at the moment of de-molding by 15% can effectively resolve sagging issues in complex geometries like one-piece toilets.
Evaluating the green body involves more than testing its Modulus of Rupture (MOR); it requires analyzing structural homogeneity.
Permeability & Wall Build-up Rate: We measure filter cake formation under 1.2 MPa pressure.
Data Support: Using Mercury Intrusion Porosimetry (MIP), we analyze pore size distribution. Research indicates that a narrower pore distribution facilitates uniform moisture migration during drying, reducing Drying Sensitivity by approximately 20%.
Firing Kinetics and Functional Validation
Dynamic Shrinkage Monitoring: We track shrinkage rates across different temperature intervals (500°C - 1200°C) rather than just the final total shrinkage.
Functional Simulation: For smart toilets, we use high-speed videography to validate the flush path. Based on , integrating fluid simulation during the testing phase can shorten mold modification cycles by 35%.