Advanced Manufacturing Solutions for Traditional Motifs: Proof of Concept Development for Islamic-Indonesian Ceramic Puzzle Tile Wall

This research develops a manufacturing solution for producing Islamic-Indonesian ceramic puzzle tile walls using Computer-Aided Design and Computer-Aided Manufacturing (CAD/CAM) technology with Computer Numerical Control (CNC) router machining. Traditional ceramic production methods present a significant challenge: conventional single-piece molds result in a 35-40% failure rate during demolding when producing complex ornamental patterns with high-relief geometric designs. This leads to substantial material waste and limits commercial viability. This study introduces a modular mold system that strategically segments Islamic-Indonesian motifs into smaller, geometrically optimized components to overcome demolding challenges while preserving aesthetic authenticity. The methodology used a four-stage approach: problem identification through forum group discussion with industry stakeholders, virtual design processing using ArtCAM Pro 2015 software for pattern analysis and 3D modeling, virtual manufacturing using Autodesk PowerMill CAM software for toolpath optimization, and comprehensive result evaluation. The research team collected 150 ornamental motifs from Islamic and Indonesian batik patterns to create ten master pattern molds and produce ceramic wall puzzle products for architectural applications. The modular mold system showed a reduction in the stuck rate from 35-40% to less than 5%, consistent dimensional accuracy with 13% shrinkage rates and error values under 0.1 mm, and a 90% reduction in production cycle time compared to traditional methods.