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Rotational molding refers to a plastic production practice that generates hollow stress-free items. The technique relies on high temperatures and bi axial rotation to come up with seamless, one piece items that have several designs, sizes and colors. This procedure is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The feature that makes this unique from other plastic manufacturing methods because no pressure is needed. It also has few contenders when it comes to the creation of large size hollow items which are resilient and inexpensive.There is a variety of items that are developed by this process including large size water tanks, automobile materials, intricate shaped medical products, leisure equipment, toys, canoes, industrial equipment among many others.This is because of the flexibility in terms of type and forms that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Bell Gardens CA 90202, 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 Bell Gardens 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 moulding operation has been used since ancient times for creatingvseverl items. Egyptians as an example, worked with roto-molding procedures in the creating of ceramics. The Swiss were also applying this rotation style to make hollow chocolate eggs. Some plastic product lines in the USA were created using this technique some time between 1940 and 1950. The technique has however taken very long to take affect because it was looked at to be a somewhat slow process
1. Mold fitting.
A fixed quantity of polymer in grain form is packed into a hollow mold. The mold is usually comprised of cast aluminium or sheet steel material. The color desired for the finished item is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this format of plastic engineering.
Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mould with the powdered polymer is then secured and positioned into the oven.
2. The heating up and fusion phase.
Once within the oven, the mould is rotated on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The spinning is done slowly and gradually, about 20 spins per min. The main thing that is critical at this point is the period of time the mold will spend within the oven. If it stays to long, the material will lose stability and durability, making a poor item. If it is extracted from the oven prematurely, the polymer will not have flowed correctly, which develops bubbles in the finalized 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 may be done by air or water, or sometimes a mixture of both which creates a cool mist. When the component cools, it shrinks a little for ease of extraction from the mold. This is an additional step that relies a lot on the ideal timing, since quick cooling reduces the material too quickly, causing warping of the item.
4. The unloading or de-moulding step.
As soon as the material within te mold has cooled correctly, the molder handling the procedure can then extract the finalized item from the mould. The function is repeated from the start, making a series of similar product lines.
For more information on the different rotational rotomolding options offered for the Bell Gardens CA 90202 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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