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Rotational moulding pertains to a plastic manufacturing solution that makes hollow stress-free products. The function depends on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have many different designs, colors and sizes. This method is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The function that makes this unique from other plastic manufacturing techniques in that no pressure is required. It also has few contenders when it comes down to the manufacture of large size hollow items which are resilient and inexpensive.There is a wide variety of items that are created by this process including big water tanks, automobile products, complex shaped medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is due to the flexibility in regards to style and shapes that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Randsburg CA 93554, 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 rotocasting 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 Randsburg 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 Roto-Molding Method in Detail
This moulding technique has been used since early times for creatingvseverl items. Egyptians for instance, employed rotational molding systems in the producing of ceramics. The Swiss were also utilizing this rotation technique to generate hollow chocolate eggs. Some plastic products in the USA were created using this procedure some time between 1940 and 1950. Given that it was regarded to be a basically slow system, the system has however taken long to become popular
1. Mould prep work.
A predetermined quantity of polymer in grain form is filled into a hollow mould. The mold is usually constructed from cast aluminium or sheet steel component. The color chosen for the final item 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 format of plastic production.
Pre-heating of the oven follows, and it can be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then sealed and placed within the oven.
2. The heating and fusion phase.
Once within the oven, the mould 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 sixty seconds. The main thing that is critical at this point is the amount of time the mould will spend inside the oven. If it overstays, the material will lose value and strength, creating a faulty item. If it is removed from the oven prematurely, the polymer will not have liquefied correctly, which creates bubbles in the finalized product line.
3. Mould cooling down.
When the component has completely spent the enough of time in the oven, it is then extracted for cooling. This can be done by air or water, or sometimes a mixture of both which generates a cool mist. When the product cools, it reduces slightly for ease of removal from the mould. This is one more measure that relies a lot on the ideal timing, since rapid cooling reduces the material too fast, causing warping of the item.
4. The offloading or de-moulding phase.
When the component inside te mould has cooled adequately, the molder taking care of the procedure can then extract the completed item from the mold. The procedure is repeated from the start, making a series of identical items.
For more information on the different rotational rotomolding options offered for the Randsburg CA 93554 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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