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Rotational molding pertains to a plastic production solution that produces hollow stress-free product lines. The method relies on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have a wide range of designs, sizes and colors. This method is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The feature that makes this unique from other plastic manufacturing techniques in that no pressure is needed. It also has few rivals when it comes to the manufacture of large size hollow items which are long lasting and inexpensive.There is a variety of product lines that are developed 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 because of the flexibility in terms of type 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 Santa Fe Springs CA 90670, 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 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 Santa Fe Springs 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 Procedure in Detail
This moulding system has been used since early times for creatingvseverl items. Egyptians for instance, used rotocasting solutions in the of ceramics. The Swiss were also making use of this rotation type to create hollow chocolate eggs. Some plastic product lines in the USA were developed using this technique some time between 1940 and 1950. The procedure has however taken very long to catch on because it was looked at as being a pretty slow process
1. Mould prep work.
A predetermined measure of polymer in particle form is loaded into a hollow mould. The mold is usually comprised of cast aluminium or sheet steel substance. The colour intended for the finished 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 manufacturing.
Preheating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mould with the powdered polymer is then locked and installed within the oven.
2. The heating up and fusion process.
Once inside the oven, the mold is rotated on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The spinning is done slowly and gradually, about 20 rotations per minute. One thing that is crucial at this moment is the amount of time the mold will spend within the oven. If it overstays, the material will lose value and strength, creating a weak item. If it is removed from the oven prematurely, the polymer will not have melted correctly, which generates bubbles in the finalized item.
3. Mould cooling.
When the product has sufficiently 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 a cool mist. When the material cools, it shrinks slightly for ease of removal from the mold. This is an additional step that relies a lot on the correct timing, since quick cooling decreases the material too quick, causing warping of the product.
4. The discharging or de-molding step.
Once the product inside te mold has cooled correctly, the person handling the process can then remove the finalized product from the mold. The procedure is repeated from the beginning, making a series of exact product lines.
For more information on the different rotational rotomolding options offered for the Santa Fe Springs CA 90670 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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