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Rotational molding refers to a plastic production method that creates hollow stress-free items. The technique uses high temperatures and bi axial rotation to come up with seamless, one piece products that have different forms, sizes and colors. This method is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The component that makes this unique from other plastic manufacturing techniques because no pressure is involved. It also has few rivals when it involves the creation of sizable hollow items which are long lasting and inexpensive.There is a wide variety of product lines that are generated by this process including large size water tanks, automobile items, complex molded medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is because of the flexibility in regards to design 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 East Hampton CT 6424, 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 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 East Hampton 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 Roto-Molding Method Components
This molding method has been used since ancient times for creatingvseverl product lines. Egyptians for example, applied rotocasting solutions in the making of ceramics. The Swiss were also making use of this rotation design to generate hollow chocolate eggs. Some plastic product lines in the USA were developed utilizing this technique some time between 1940 and 1950. The procedure has however taken long to catch on because it was considered to be a somewhat slow process
1. Mould readying.
A fixed volume of polymer in grain form is filled into a hollow mould. The mold is usually made from cast aluminium or sheet steel component. The coloring preferred for the end item is pre compounded into the polymer. The most generally used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic assembly.
Pre-heating of the oven starts, and it may 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 sealed and placed inside the oven.
2. The heating and fusion phase.
Once within the oven, the mould is rotated on two axis so the powdered polymer liquefies from the heat and layers the inside if the mold. The turning is done slowly and gradually, about 20 rotations per minute. The main thing that is critical at this point is the amount of time the mold will spend inside the oven. If it stays to long, the product will lose value and strength, generating a weak product. If it is extracted from the oven too early, the polymer will not have melted correctly, which creates bubbles in the finalized product line.
3. Mould cooling down.
When the material has sufficiently 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 creates a cool mist. When the component cools, it reduces a little for ease of removal from the mold. This is another measure that depends a lot on the ideal timing, since quick cooling reduces the material too quick, causing bending of the material.
4. The unloading or de-moulding phase.
Once the component within te mold has cooled effectively, the molder managing the operation can then extract the finished item from the mold. The procedure is repeated from the beginning, making a number of identical products.
For more information on the different rotational rotomolding options offered for the East Hampton CT 6424 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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