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Rotational moulding pertains to a plastic manufacturing solution that produces hollow stress-free items. The method utilizes high temperatures and bi axial rotation to follow up with seamless, one piece items that have many different forms, sizes and colors. This procedure is also called rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The feature that makes this different from other plastic manufacturing methods because no pressure is needed. It also has few rivals when it comes to the manufacture of large size hollow items which are resilient and inexpensive.There is a wide range of product lines that are developed by this process including large size water tanks, automobile products, complex molded medical items, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in terms of type and shapes that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Aptos CA 95001, 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 Aptos 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 Rotomoulding Procedure Components
This moulding procedure has been used since ancient times for creatingvseverl products. Egyptians as an example, utilized rotomoulding solutions in the producing of ceramics. The Swiss were also utilizing this rotation format to create hollow chocolate eggs. Some plastic items in the USA were created utilizing this procedure some time between 1940 and 1950. Since it was looked at to be a fairly slow procedure, the technique has however taken long to become popular
1. Mould readying.
A predetermined quantity of polymer in particle form is loaded into a hollow mould. The mould is usually made from cast aluminium or sheet steel component. The color preferred for the finished item 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 type of plastic manufacturing.
Pre-heating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mould with the powdered polymer is then locked and inserted inside the oven.
2. The heating and fusion step.
Once inside the oven, the mould is turned on two axis so the powdered polymer liquefies from the heat and coats the inside if the mould. The spinning is done gradually, about 20 revolutions per minute. Something that is critical at this moment is the amount of time the mould will spend inside the oven. If it overstays, the material will lose stability and strength, generating a faulty item. If it is extracted from the oven prematurely, the polymer will not have liquefied properly, which develops bubbles in the completed product line.
3. Mold cooling.
When the material has completely spent the enough of time in the oven, it is then extracted for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the component cools, it shrinks a little for ease of extraction from the mold. This is yet another procedure that depends upon a lot on the right timing, since quick cooling decreases the material too quickly, causing bending of the item.
4. The unloading or de-molding phase.
When the material within te mold has cooled correctly, the person handling the operation can then take out the finalized item from the mould. The procedure is repeated from the beginning, making a series of similar products.
For more information on the different rotational rotomolding options offered for the Aptos CA 95001 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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