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Rotational moulding pertains to a plastic production practice that produces hollow stress-free product lines. The function utilizes high temperatures and bi axial rotation to come up with seamless, one piece objects that have a wide range of shapes, colors and sizes. This method is also referred to as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The benefit that makes this different from other plastic manufacturing methods because no pressure is called for. It also has few contenders when it involves the production of large size hollow products which are long-lasting and inexpensive.There is a wide range of items that are generated by this process including big water tanks, automobile products, complex designed medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is because of the versatility in terms of 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 Clements CA 95227, 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 Clements 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 Rotomolding Method Components
This moulding process has been used since earlier times for creatingvseverl items. Egyptians for instance, applied roto-molding solutions in the making of ceramics. The Swiss were also utilizing this rotation approach to create hollow chocolate eggs. Some plastic product lines in the USA were made using this approach some time between 1940 and 1950. Due to the fact that it was regarded to be a fairly slow-moving process, the method has however taken long to catch on
1. Mold fitting.
A predetermined amount of polymer in grain form is packed into a hollow mould. The mould is usually made from cast aluminium or sheet steel component. The color tone chosen for the end 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 design of plastic manufacturing.
Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then secured and inserted inside the oven.
2. The heating and fusion step.
Once placed into the oven, the mould is spun 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 rotations per min. Something that is important at this moment is the period of time the mold will spend within the oven. If it overstays, the component will lose value and strength, making a faulty item. If it is taken out from the oven too early, the polymer will not have flowed properly, which generates bubbles in the finished product.
3. Mould cooling.
When the component has sufficiently spent the correct amount 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 material cools, it shrinks a little for ease of removal from the mould. This is an additional procedure that depends a lot on the correct timing, since quick cooling reduces the material too rapidly, causing warping of the item.
4. The offloading or de-moulding step.
When the material inside te mould has cooled successfully, the person handling the procedure can then remove the completed item from the mould. The function is repeated from the start, giving a series of exact products.
For more information on the different rotational rotomolding options offered for the Clements CA 95227 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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