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Rotational molding pertains to a plastic manufacturing practice that makes 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 various shapes, sizes and colors. This technique is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The benefit that makes this different from other plastic manufacturing procedures that no pressure is involved. It also has few contenders when it comes to the production of large size hollow products which are resilient and inexpensive.There is a wide range of product lines that are produced by this process including big water tanks, automobile products, sophisticated designed medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is due to the flexibility in regards to design 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 Azusa CA 91702, 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 rotocasting 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 Azusa 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 Components
This moulding method has been used since early times for creatingvseverl products. Egyptians for instance, worked with rotational molding systems in the making of ceramics. The Swiss were also utilizing this rotation style to generate hollow chocolate eggs. Some plastic product lines in the USA were created using this method some time between 1940 and 1950. The process has however taken very long to take affect because it was thought of as being a relatively slow process
1. Mold readying.
A fixed quantity of polymer in particle form is filled into a hollow mold. The mould is usually made of cast aluminium or sheet steel substance. The coloring desired for the end product is pre compounded into the polymer. The most typically used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this format of plastic engineering.
Preheating of the oven starts, and it can 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 sealed and inserted within the oven.
2. The heating and fusion process.
Once within the oven, the mold is spun on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The turning is done slowly and gradually, about 20 rotations per min. Something that is vital at this point is the amount of time the mould will spend within the oven. If it stays to long, the product will lose value and durability, making a poor item. If it is extracted from the oven too early, the polymer will not have liquefied correctly, which generates bubbles in the completed item.
3. Mould cooling down.
When the component has completely spent the correct amount 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 generates a cool mist. When the component cools, it shrinks somewhat for ease of removal from the mould. This is another measure that relies a lot on the right timing, since quick cooling reduces the material too rapidly, causing bending of the product.
4. The offloading or de-moulding phase.
When the material inside te mould has cooled effectively, the person handling the process can then remove the completed item from the mold. The technique is repeated from the start, making a series of identical products.
For more information on the different rotational rotomolding options offered for the Azusa CA 91702 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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