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Rotational moulding refers to a plastic manufacturing procedure that creates hollow stress-free products. The method uses high temperatures and bi axial rotation to come up with seamless, one piece products that have many different designs, colors and sizes. This technique is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The feature that makes this unique from other plastic manufacturing procedures because no pressure is required. It also has few contenders when it involves the production of sizable hollow products which are long-lasting and inexpensive.There is a variety of items that are generated by this process including large water tanks, automobile products, intricate designed medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is because of the flexibility in terms of type 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 Frisco CO 80443, 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 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 Frisco 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 Roto-Molding Method Components
This molding procedure has been used since early times for creatingvseverl items. Egyptians as an example, utilized rotational molding procedures in the creating of ceramics. The Swiss were also working with this rotation method to generate hollow chocolate eggs. Some plastic product lines in the USA were manufactured utilizing this approach some time between 1940 and 1950. Given that it was regarded to be a relatively slow technique, the system has however taken long to become popular
1. Mould fitting.
A predetermined volume of polymer in particle form is loaded into a hollow mold. The mould is usually made of cast aluminium or sheet steel material. The colour needed for the end 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 format of plastic production.
Pre-heating of the oven follows, and it can 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 sealed and put inside the oven.
2. The heat and fusion step.
Once inside the oven, the mold is revolved on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The spinning is done gradually, about 20 rotations per min. The main thing that is critical at this moment is the amount of time the mold will spend within the oven. If it overstays, the product will lose value and durability, making a poor product. If it is removed from the oven prematurely, the polymer will not have flowed correctly, which creates bubbles in the finished item.
3. Mold cooling.
When the material has completely spent the correct amount 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 generates a cool mist. When the product cools, it shrinks slightly for ease of extraction from the mould. This is an additional step that depends a lot on the right timing, since quick cooling shrinks the material too fast, causing warping of the item.
4. The removing or de-molding step.
When the component within te mold has cooled effectively, the person taking care of the process can then extract the completed product from the mold. The technique is repeated from the beginning, supplying a series of exact items.
For more information on the different rotational rotomolding options offered for the Frisco CO 80443 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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