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Rotational molding pertains to a plastic production technique that creates hollow stress-free product lines. The function relies on high temperatures and bi axial rotation to come up with seamless, one piece items that have varying designs, colors and sizes. This method is also known as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The feature that makes this unique from other plastic manufacturing techniques that no pressure is needed. It also has few competitors when it pertains to the manufacture of large size hollow products which are long lasting and inexpensive.There is a wide variety of products that are created by this process including large size water tanks, automobile materials, intricate shaped medical products, recreation equipment, toys, kayaks, industrialized equipment among many others.This is due to the flexibility 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 Citrus Heights CA 95610, 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 Citrus Heights 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 molding procedure has been used since early times for creatingvseverl items. Egyptians as an example, utilized roto-molding solutions in the creating of ceramics. The Swiss were also using this rotation format to make hollow chocolate eggs. Some plastic items in the USA were made utilizing this technique some time between 1940 and 1950. Given that it was regarded to be a rather slow process, the approach has however taken long to catch on
1. Mold preparation.
A fixed measure of polymer in powder form is filled into a hollow mold. The mould is usually crafted from cast aluminium or sheet steel material. The coloring needed for the finished 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 engineering.
Preheating of the oven follows, and it can be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mould with the powdered polymer is then secured and positioned within the oven.
2. The heat and fusion process.
Once inside the oven, the mould is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The turning is done slowly and gradually, about 20 rotations per sixty seconds. The main thing that is crucial at this point is the amount of time the mold will spend inside the oven. If it stays to long, the component 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 finalized product line.
3. Mould cooling down.
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 material cools, it reduces slightly for ease of extraction from the mold. This is an additional procedure that depends upon a lot on the ideal timing, since rapid cooling reduces the material too quickly, causing warping of the item.
4. The un-loading or de-molding step.
As soon as the product within te mold has cooled correctly, the molder taking care of the operation can then take out the finalized product from the mould. The function is repeated from the start, making a series of identical product lines.
For more information on the different rotational rotomolding options offered for the Citrus Heights CA 95610 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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