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Rotational molding pertains to a plastic production method that makes hollow stress-free products. The procedure utilizes high temperatures and bi axial rotation to follow up with seamless, one piece products that have various forms, sizes and colors. This method is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The component that makes this different from other plastic manufacturing methods in that no pressure is needed. It also has few contenders when it comes down to the manufacture of sizable hollow items which are resilient and inexpensive.There is a wide range of products that are produced by this process including big water tanks, automobile materials, complex molded medical items, leisure equipment, toys, canoes, industrialized equipment among many others.This is due to the versatility in terms of design and forms that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Brookfield CT 6804, 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 Connecticut 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 Brookfield Connecticut 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 Method Components
This moulding process has been used since earlier times for creatingvseverl items. Egyptians for instance, applied rotomoulding methods in the manufacturing of ceramics. The Swiss were also utilizing this rotation technique to generate hollow chocolate eggs. Some plastic product lines in the USA were manufactured utilizing this technique some time between 1940 and 1950. Considering that it was considered to be a very slow method, the process has however taken long to become popular
1. Mold fitting.
A fixed amount of polymer in particle form is packed into a hollow mold. The mould is usually composeded of cast aluminium or sheet steel material. 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 style of plastic production.
Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mold with the powdered polymer is then secured and installed inside the oven.
2. The heating up and fusion process.
Once within the oven, the mold is turned on two axis so the powdered polymer liquefies from the heat and coats the inside if the mould. The rotation is done slowly, about 20 spins per min. One thing that is vital at this point is the amount of time the mould will spend within the oven. If it overstays, the component will lose value and durability, generating a poor item. If it is extracted from the oven too early, the polymer will not have flowed correctly, which produces bubbles in the finalized product.
3. Mould cooling down.
When the material has sufficiently spent the correct amount 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 creates a cool mist. When the component cools, it shrinks somewhat for ease of removal from the mould. This is one more measure that depends a lot on the ideal timing, since quick cooling reduces the material too fast, causing bending of the product.
4. The offloading or de-molding phase.
When the material within te mold has cooled adequately, the molder taking care of the operation can then take out the finalized product from the mold. The procedure is repeated from the beginning, making a number of similar products.
For more information on the different rotational rotomolding options offered for the Brookfield CT 6804 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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