It should not be hard at all to make small ceramic washers. I would use a
slip casting method. I would start with a plaster of paris sheet poured
into a rectangular wood box. The top edges of the wood sides of the box
allow you to scrape the poured plaster of paris sheet to have a flat top
surface. Plaster of paris is easy to work when it is still damp. Then use
a counter bore or make a simple flat bottomed cutter similar to a wood
paddle drill. Make a whole lot of flat bottomed dimples (or maybe curved
bottom dimples if you want convex washers) Get some porcelain slip and
pour it on top of the plaster of paris slab. Squeegee the excess slip off.
Let the slip harden to leather hardness. Use a pin or small drill bit to
put the hole in the center of each disk of leather hard porcelain slip.
Let the slip keep drying. The slip will shrink and pull away from the
plaster. After a while you should be able to tip over the slab and have
all the washers fall out. A simple table top kiln would be used to fire
the porcelain. You could build one for well under $100 worth of parts.
Tim Laing
BFA in Ceramics
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