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Rotational molding refers to a plastic production solution that makes hollow stress-free products. The method uses high temperatures and bi axial rotation to come up with seamless, one piece objects that have many different designs, sizes and colors. This technique is also known as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The benefit that makes this different from other plastic manufacturing methods in that no pressure is involved. It also has few rivals when it comes down to the production of large hollow items which are durable and inexpensive.There is a wide variety of products that are generated by this process including big water tanks, automobile products, intricate designed medical items, recreation equipment, toys, kayaks, industrialized equipment among many others.This is because of the flexibility in regards to style and forms that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Alviso CA 95002, 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 roto-molding 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 California 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 Alviso California 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 Method Components
This moulding procedure has been used since earlier times for creatingvseverl product lines. Egyptians as an example, utilized rotomoulding procedures in the creating of ceramics. The Swiss were also working with this rotation type to create hollow chocolate eggs. Some plastic items in the USA were developed utilizing this approach some time between 1940 and 1950. Given that it was regarded to be a relatively slow-moving system, the technique has however taken long to become popular
1. Mold preparation.
A predetermined quantity of polymer in particle form is filled into a hollow mold. The mold is usually built from cast aluminium or sheet steel component. The coloration desired 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 format of plastic assembly.
Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mould with the powdered polymer is then sealed and inserted inside the oven.
2. The heat and fusion procedure.
Once placed into the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The turning is done gradually, about 20 spins per min. One thing that is crucial at this point is the period of time the mold will spend inside the oven. If it overstays, the product will lose stability and strength, creating a faulty product. If it is taken out from the oven too early, the polymer will not have melted properly, which creates bubbles in the finished item.
3. Mold cooling.
When the component has completely spent the correct amount of time in the oven, it is then taken out for cooling. This may be done by air or water, or sometimes a mixture of both which generates a cool mist. When the material cools, it reduces slightly for ease of removal from the mold. This is another step that depends a lot on the correct timing, since rapid cooling decreases the material too quick, causing warping of the product.
4. The un-loading or de-molding step.
As soon as the product within te mold has cooled adequately, the person handling the procedure can then extract the completed product from the mold. The procedure is repeated from the beginning, giving a series of identical products.
For more information on the different rotational rotomolding options offered for the Alviso CA 95002 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
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