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Rotational moulding pertains to a plastic manufacturing procedure that generates hollow stress-free items. The function depends on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have different shapes, colors and sizes. This method is also referred to as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The function that makes this unique from other plastic manufacturing methods because no pressure is needed. It also has few rivals when it comes down to the manufacture of sizable hollow items which are long-lasting and inexpensive.There is a wide range of product lines that are produced by this process including large size water tanks, automobile items, sophisticated designed medical products, recreation equipment, toys, kayaks, industrialized equipment among many others.This is due to the flexibility in regards to style and shapes that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Atherton CA 94027, 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 Atherton 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 Method in Detail
This molding procedure has been used since earlier times for creatingvseverl product lines. Egyptians as an example, utilized roto-molding procedures in the producing of ceramics. The Swiss were also employing this rotation style 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 long to take affect because it was thought of to be a moderately slow process
1. Mould fitting.
A predetermined amount of polymer in powder form is filled into a hollow mould. The mold is usually made from cast aluminium or sheet steel substance. The color tone chosen for the final product 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.
Preheating of the oven follows, and it can be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mold with the powdered polymer is then locked and put inside the oven.
2. The heat and fusion procedure.
Once placed into the oven, the mould is spun on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The rotation is done slowly and gradually, about 20 revolutions per min. Something that is essential at this moment is the period of time the mould will spend inside the oven. If it stays to long, the product will lose value and durability, generating a poor product. If it is extracted from the oven too early, the polymer will not have liquefied correctly, which produces bubbles in the completed product line.
3. Mold cooling.
When the material has completely spent the right amount of time in the oven, it is then removed for cooling. This may be done by air or water, or sometimes a mixture of both which generates a cool mist. When the product cools, it shrinks slightly for ease of extraction from the mold. This is another step that depends upon a lot on the correct timing, since rapid cooling reduces the material too quickly, causing bending of the product.
4. The unloading or de-moulding step.
As soon as the product inside te mold has cooled properly, the person managing the process can then take out the finalized item from the mould. The function is repeated from the start, making a series of exact product lines.
For more information on the different rotational rotomolding options offered for the Atherton CA 94027 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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