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Rotational molding pertains to a plastic manufacturing method that makes hollow stress-free product lines. The technique relies on high temperatures and bi axial rotation to follow up with seamless, one piece items that have many different shapes, sizes and colors. This procedure is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The benefit that makes this different from other plastic manufacturing methods because no pressure is required. It also has few contenders when it comes down to the production of large hollow products which are long-lasting and inexpensive.There is a variety of products that are generated by this process including large size water tanks, automobile items, complex shaped medical products, recreation equipment, toys, kayaks, industrial equipment among many others.This is due to the versatility in terms of type and forms that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Davis CA 95616, 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 Davis 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 moulding method has been used since ancient times for creatingvseverl products. Egyptians as an example, worked with rotocasting methods in the producing of ceramics. The Swiss were also employing this rotation technique to create hollow chocolate eggs. Some plastic product lines in the USA were developed using this procedure some time between 1940 and 1950. The process has however taken very long to catch on because it was thought of to be a rather slow-moving process
1. Mould preparation.
A predetermined quantity of polymer in grain form is packed into a hollow mold. The mould is usually built from cast aluminium or sheet steel substance. The color tone needed for the end product 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 design of plastic production.
Pre-heating of the oven follows, 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 secured and positioned within the oven.
2. The heating up and fusion procedure.
Once placed into the oven, the mold is spun on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The spinning is done gradually, about 20 rotations per minute. The main thing that is crucial at this point is the amount of time the mould will spend within the oven. If it stays to long, the component will lose stability and durability, making a weak item. If it is removed from the oven too early, the polymer will not have flowed correctly, which creates bubbles in the finished product.
3. Mold cooling.
When the product has completely spent the right amount of time in the oven, it is then removed for cooling. This may be done by air or water, or sometimes a mixture of both which a cool mist. When the component cools, it reduces a little for ease of removal from the mold. This is one more measure that depends a lot on the correct timing, since rapid cooling shrinks the material too quick, causing warping of the product.
4. The discharging or de-molding phase.
As soon as the material within te mold has cooled adequately, the person taking care of the operation can then remove the completed product from the mould. The technique is repeated from the beginning, making a number of similar products.
For more information on the different rotational rotomolding options offered for the Davis CA 95616 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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