Looking for rotational molding alternatives for Alabama? Want affordable custom plastic molding that is cost effective for Butler area? Then give us a call at our toll free number 866-971-7861 or request a quote today!
Rotational moulding pertains to a plastic manufacturing method that produces hollow stress-free product lines. The function relies upon high temperatures and bi axial rotation to come up with seamless, one piece products that have a variety of forms, colors and sizes. This method is also known as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The function that makes this unique from other plastic manufacturing processes in that no pressure is needed. It also has few contenders when it pertains to the creation of large size hollow products which are resilient and inexpensive.There is a variety of product lines that are generated by this process including big water tanks, automobile items, sophisticated molded medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is because of the flexibility in terms of style and shapes that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Butler AL 36904, it is a cheaper way of making plastics. This is because apart from the fact that no pressure is required, the cost of mold preparation is low.
- – A wide array of design options.
There is no limit to the kind of design one may want to create. The rotational moulding process therefore allows for the manufacturing of products that have complex shapes for different purposes.
- – Size.
The process provides room for the manufacturing of products of any size, large or small. As mentioned earlier, it has few competitors when it comes to the making of large tanks at low costs.
- – Low risk.
Due to the low costs of creating a mould, the process allows for test runs before one can decide whether to do mass production. It therefore minimizes the risk of losing a lot of investment.
- – Durable products.
The process allows for even coating of the mould with the heated polymer, giving the product a wall with uniform thickness. It also gives the option of double coating for increased durability. Sometimes metal inserts are placed inside the mould to further strengthen the product.
- – Environmentally friendly.
There is no waste that could have a negative impact on the environment because the products that cannot be used are reground and reused as polymer.
Examples of Products Made by Rotational Molding
Rotocasting is a very versatile process, making it possible to create a variety of products for different industries.
- Agricultural industry– From cattle feeders, water troughs, spray tanks etc.
- Automotive industry– Filler tubes, dash boards, arm rests, sun visors, air conditioner duct work etc.
- Furniture– We have plastic cabinets, chairs and tables made from this form of moulding.
There are numerous Alabama plastic products also that have been made for the marine industry, lighting, waste storage and transportation, kayaks etc.
Few Disadvantages – There are nominal disadvantages that have been associated with rotocasting. For instance:
- – The process is relatively slow when compared to injection moulding.
- – There is a limitation when it comes to the type of raw material you can use. Only poly based and nylon polymers can be used.
- – The process comes with an increased cost because the polymer has to be ground to powder form before use.
These limitations are often overlooked considering that the process is still relatively cheap and offers more in terms of variety when it comes to the finished range of products.
Remember – There are new developments and discoveries that are being made as the world of plastic manufacturing in Butler Alabama continuously. For instance, tests are being done to see whether there are other materials that can be used for this process. But so far, rotomoulding offers a good option for the production of a wide range of inexpensive plastic products.
The Rotomolding Procedure in Detail
This molding procedure has been used since earlier times for creatingvseverl products. Egyptians for instance, used rotomoulding techniques in the making of ceramics. The Swiss were also using this rotation method to make hollow chocolate eggs. Some plastic items in the USA were manufactured utilizing this technique some time between 1940 and 1950. Since it was looked at to be a somewhat slow-moving technique, the process has however taken long to catch on
1. Mold fitting.
A predetermined quantity of polymer in particle form is loaded into a hollow mold. The mould is usually made from cast aluminium or sheet steel component. The colour preferred for the end product is pre compounded into the polymer. The most commonly used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this style of plastic production.
Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mould with the powdered polymer is then sealed and positioned within the oven.
2. The heat and fusion phase.
Once within the oven, the mould is turned on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The rotation is done slowly, about 20 rotations per min. The main thing that is critical at this point is the amount of time the mold will spend inside the oven. If it stays to long, the product will lose value and durability, generating a weak product. If it is removed from the oven too early, the polymer will not have flowed correctly, which produces bubbles in the completed product line.
3. Mould cooling.
When the material has sufficiently spent the enough of time in the oven, it is then taken out for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the product cools, it reduces slightly for ease of removal from the mold. This is an additional measure that relies a lot on the ideal timing, since quick cooling reduces the material too quick, causing bending of the material.
4. The removing or de-moulding step.
Once the product inside te mold has cooled effectively, the molder taking care of the process can then extract the finished product from the mould. The process is repeated from the start, making a series of similar items.
For more information on the different rotational rotomolding options offered for the Butler AL 36904 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
Other areas we service, go here to custom molded