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Rotational moulding pertains to a plastic production technique that produces hollow stress-free product lines. The procedure utilizes high temperatures and bi axial rotation to follow up with seamless, one piece items that have different forms, sizes and colors. This method is also referred to as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The benefit that makes this different from other plastic manufacturing processes because no pressure is needed. It also has few rivals when it comes to the creation of large hollow products which are long lasting and inexpensive.There is a variety of product lines that are generated by this process including big water tanks, automobile items, complex molded medical items, recreation equipment, toys, kayaks, industrial equipment among many others.This is due to the flexibility in regards to style and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Black Hawk CO 80422, 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 Colorado 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 Black Hawk Colorado 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 Process in Detail
This molding system has been used since earlier times for creatingvseverl product lines. Egyptians as an example, utilized roto-molding solutions in the making of ceramics. The Swiss were also employing this rotation design to generate hollow chocolate eggs. Some plastic items in the USA were created using this method some time between 1940 and 1950. Considering that it was looked at to be a fairly slow-moving procedure, the technique has however taken long to become popular
1. Mold preparation.
A predetermined amount of polymer in powder form is filled into a hollow mold. The mold is usually made from cast aluminium or sheet steel component. The colour desired for the finished item is pre compounded into the polymer. The most often 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 to temperatures between 500-700F. The mold with the powdered polymer is then secured and positioned within the oven.
2. The heating up and fusion phase.
Once inside the oven, the mold is spun on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The spinning is done gradually, about 20 revolutions per minute. One thing that is essential at this moment is the amount of time the mould will spend inside the oven. If it overstays, the component will lose value and strength, creating a poor product. If it is removed from the oven prematurely, the polymer will not have liquefied properly, which creates bubbles in the finalized product.
3. Mould cooling down.
When the material has completely spent the enough of time in the oven, it is then taken out for cooling. This can be done by air or water, or sometimes a mixture of both which generates a cool mist. When the component cools, it reduces slightly for ease of removal from the mould. This is yet another procedure that depends upon a lot on the correct timing, since quick cooling decreases the material too quickly, causing warping of the product.
4. The discharging or de-molding step.
When the component within te mold has cooled adequately, the molder handling the process can then extract the finished item from the mold. The function is repeated from the beginning, giving a number of similar products.
For more information on the different rotational rotomolding options offered for the Black Hawk CO 80422 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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