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Rotational moulding pertains to a plastic manufacturing practice that creates hollow stress-free products. The method uses high temperatures and bi axial rotation to follow up with seamless, one piece products that have a wide range of shapes, colors and sizes. This method is also known as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The feature that makes this unique from other plastic manufacturing methods that no pressure is needed. It also has few competitors when it comes to the creation of sizable hollow products which are resilient and inexpensive.There is a wide variety of product lines that are generated by this process including large water tanks, automobile materials, sophisticated shaped medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the versatility in terms of style 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 Camarillo CA 93010, 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 rotomoulding 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 Camarillo 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 technique has been used since ancient times for creatingvseverl product lines. Egyptians as an example, used rotocasting systems in the making of ceramics. The Swiss were also applying this rotation method to make hollow chocolate eggs. Some plastic items in the USA were developed utilizing this technique some time between 1940 and 1950. The system has however taken very long to catch on because it was looked at to be a somewhat slow-moving process
1. Mould preparation.
A predetermined volume of polymer in grain form is filled into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel substance. The color tone preferred for the end 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 design of plastic production.
Preheating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then locked and inserted inside the oven.
2. The heat and fusion procedure.
Once inside the oven, the mould is rotated on two axis so the powdered polymer liquefies from the heat and layers the inside if the mold. The turning is done slowly, about 20 revolutions per sixty seconds. The main thing that is important at this moment is the period of time the mould will spend within the oven. If it overstays, the material will lose stability and durability, generating a weak item. If it is extracted from the oven too early, the polymer will not have liquefied properly, which generates bubbles in the finalized product line.
3. Mould cooling down.
When the material has sufficiently spent the right amount of time in the oven, it is then taken out for cooling. This can 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 removal from the mold. This is an additional step that depends a lot on the ideal timing, since quick cooling decreases the material too fast, causing warping of the product.
4. The unloading or de-molding step.
As soon as the material inside te mold has cooled correctly, the molder handling the process can then take out the completed item from the mold. The function is repeated from the start, making a series of exact products.
For more information on the different rotational rotomolding options offered for the Camarillo CA 93010 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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