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Rotational moulding refers to a plastic production technique that generates hollow stress-free product lines. The method relies upon high temperatures and bi axial rotation to come up with seamless, one piece objects that have several forms, colors and sizes. This procedure is also referred to as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The attribute that makes this unique from other plastic manufacturing methods that no pressure is involved. It also has few rivals when it comes to the manufacture of large hollow items which are resilient and inexpensive.There is a variety of items that are created by this process including big water tanks, automobile materials, intricate shaped medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is due to the versatility in regards to style and shapes that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Castaic CA 91310, 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 Castaic 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 Process in Detail
This moulding system has been used since early times for creatingvseverl items. Egyptians as an example, applied rotomoulding systems in the manufacturing of ceramics. The Swiss were also working with this rotation format to generate hollow chocolate eggs. Some plastic product lines in the USA were manufactured utilizing this technique some time between 1940 and 1950. The system has however taken long to catch on because it was thought of as being a rather slow process
1. Mould fitting.
A predetermined amount of polymer in particle form is filled 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 design of plastic manufacturing.
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 mould with the powdered polymer is then sealed and placed inside the oven.
2. The heating and fusion procedure.
Once inside the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The rotation is done slowly and gradually, about 20 revolutions per sixty seconds. Something that is critical at this point is the period of time the mould will spend inside the oven. If it stays to long, the material will lose value and durability, generating a weak item. If it is removed from the oven too early, the polymer will not have flowed correctly, which produces bubbles in the finished product.
3. Mould cooling.
When the material has completely spent the right amount of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the product cools, it shrinks a little for ease of extraction from the mold. This is an additional step that depends upon a lot on the ideal timing, since quick cooling reduces the material too rapidly, causing warping of the item.
4. The offloading or de-molding step.
Once the component within te mold has cooled successfully, the person managing the operation can then take out the finished item from the mould. The procedure is repeated from the beginning, giving a series of identical product lines.
For more information on the different rotational rotomolding options offered for the Castaic CA 91310 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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