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Rotational molding pertains to a plastic production solution that generates hollow stress-free product lines. The procedure utilizes high temperatures and bi axial rotation to follow up with seamless, one piece products that have various forms, sizes and colors. This method is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The benefit that makes this unique from other plastic manufacturing techniques that no pressure is needed. It also has few rivals when it comes down to the creation of sizable hollow items which are resilient and inexpensive.There is a wide variety of product lines that are generated by this process including big water tanks, automobile materials, complex designed medical items, leisure equipment, toys, canoes, industrialized equipment among many others.This is because of the flexibility in terms of design 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 Annapolis CA 95412, 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 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 Annapolis 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 Roto-Molding Method in Detail
This molding method has been used since earlier times for creatingvseverl product lines. Egyptians for example, used roto-molding methods in the producing of ceramics. The Swiss were also utilizing this rotation design to create hollow chocolate eggs. Some plastic products in the USA were made utilizing this procedure some time between 1940 and 1950. The procedure has however taken very long to catch on because it was considered as being a moderately slow process
1. Mould readying.
A fixed volume of polymer in grain form is packed into a hollow mold. The mould is usually built from cast aluminium or sheet steel substance. The coloration chosen for the final goods is pre compounded into the polymer. The most generally used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this style 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 secured and put within the oven.
2. The heat and fusion phase.
Once placed into the oven, the mould is turned on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The turning is done slowly and gradually, about 20 spins per min. The main thing that is essential at this point is the amount of time the mould will spend inside the oven. If it stays to long, the product will lose value and strength, generating a poor product. If it is extracted from the oven prematurely, the polymer will not have liquefied properly, which develops bubbles in the finished product.
3. Mould cooling.
When the component has completely spent the right amount of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the material cools, it shrinks somewhat for ease of extraction from the mould. This is one more measure that depends a lot on the correct timing, since quick cooling reduces the material too quickly, causing warping of the product.
4. The unloading or de-molding step.
As soon as the product within te mould has cooled effectively, the molder managing the procedure can then extract the completed product from the mold. The procedure is repeated from the beginning, giving a series of exact product lines.
For more information on the different rotational rotomolding options offered for the Annapolis CA 95412 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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