Looking for rotational molding alternatives for California? Want affordable custom plastic molding that is cost effective for Colfax area? Then give us a call at our toll free number 866-971-7861 or request a quote today!
Rotational molding pertains to a plastic production practice that makes hollow stress-free product lines. The method relies on high temperatures and bi axial rotation to come up with seamless, one piece products that have many different designs, colors and sizes. This method is also known as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The benefit that makes this unique from other plastic manufacturing techniques because no pressure is needed. It also has few competitors when it pertains to the manufacture of large size hollow items which are durable and inexpensive.There is a wide range of items that are created by this process including large water tanks, automobile products, sophisticated designed medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in regards to design and shapes that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Colfax CA 95713, 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 Colfax 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 items. Egyptians as an example, worked with rotomoulding systems in the creating of ceramics. The Swiss were also making use of this rotation format to create hollow chocolate eggs. Some plastic items in the USA were created using 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 relatively slow-moving process
1. Mold fitting.
A fixed quantity of polymer in powder form is packed into a hollow mould. The mold is usually comprised of cast aluminium or sheet steel material. The coloring desired for the end 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 design of plastic engineering.
Pre-heating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mould with the powdered polymer is then sealed and installed inside the oven.
2. The heat and fusion procedure.
Once placed into the oven, the mold is spun on two axis so the powdered polymer liquefies from the heat and coats the inside if the mould. The spinning is done slowly and gradually, about 20 rotations per min. Something that is crucial at this point is the period of time the mold will spend within the oven. If it overstays, the component will lose value and durability, creating a faulty product. If it is extracted from the oven too early, the polymer will not have flowed correctly, which creates bubbles in the completed item.
3. Mould cooling.
When the product 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 generates a cool mist. When the material cools, it shrinks somewhat for ease of extraction from the mould. This is another procedure that depends a lot on the ideal timing, since quick cooling decreases the material too rapidly, causing warping of the product.
4. The un-loading or de-moulding phase.
When the product within te mold has cooled correctly, the person taking care of the process can then take out the completed item from the mould. The procedure is repeated from the start, supplying a series of similar items.
For more information on the different rotational rotomolding options offered for the Colfax CA 95713 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
Other areas we service, go here to custom molding