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Rotational moulding pertains to a plastic manufacturing practice that generates hollow stress-free items. The process relies upon high temperatures and bi axial rotation to come up with seamless, one piece products that have different shapes, sizes and colors. This method is also referred to as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The component that makes this different from other plastic manufacturing techniques in that no pressure is needed. It also has few competitors when it involves the creation of large hollow items which are long-lasting and inexpensive.There is a wide variety of product lines that are created by this process including large water tanks, automobile items, sophisticated molded medical items, recreation equipment, toys, canoes, industrial equipment among many others.This is due to 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 Corona CA 91718, 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 rotomolding 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 Corona 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 method has been used since earlier times for creatingvseverl products. Egyptians for example, applied rotocasting procedures in the manufacturing of ceramics. The Swiss were also making use of this rotation method to make hollow chocolate eggs. Some plastic products in the USA were made utilizing this approach some time between 1940 and 1950. The technique has however taken very long to take affect because it was looked at as being a rather slow-moving process
1. Mold readying.
A predetermined measure of polymer in grain form is filled into a hollow mold. The mould is usually made of cast aluminium or sheet steel material. The colour needed for the finished goods is pre compounded into the polymer. The most commonly used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this type of plastic production.
Pre-heating 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 sealed and positioned into the oven.
2. The heating up and fusion procedure.
Once inside the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The rotation is done gradually, about 20 rotations per minute. Something that is important at this point is the period of time the mold will spend within the oven. If it stays to long, the component will lose stability and strength, producing a weak product. If it is removed from the oven too early, the polymer will not have melted correctly, which generates bubbles in the completed 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 creates a cool mist. When the product cools, it reduces slightly for ease of removal from the mold. This is yet another step that depends a lot on the correct timing, since quick cooling reduces the material too quickly, causing bending of the product.
4. The un-loading or de-moulding step.
Once the product within te mold has cooled properly, the molder taking care of the procedure can then remove the finished product from the mould. The technique is repeated from the beginning, supplying a series of identical items.
For more information on the different rotational rotomolding options offered for the Corona CA 91718 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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