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Rotational moulding pertains to a plastic production procedure that creates hollow stress-free product lines. The function utilizes high temperatures and bi axial rotation to follow up with seamless, one piece objects that have various forms, colors and sizes. This technique is also called rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The function that makes this unique from other plastic manufacturing methods because no pressure is required. It also has few competitors when it involves the creation of large hollow items which are durable and inexpensive.There is a wide range of product lines that are generated by this process including big water tanks, automobile products, complex molded medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is because of the flexibility in regards to style and forms that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Hamden CT 6514, 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 rotomoulding 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 Hamden 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 Rotomoulding Method in Detail
This molding method has been used since ancient times for creatingvseverl product lines. Egyptians for instance, employed rotomoulding procedures in the producing of ceramics. The Swiss were also applying this rotation type to create hollow chocolate eggs. Some plastic items in the USA were created utilizing this approach some time between 1940 and 1950. The system has however taken very long to take affect because it was looked at to be a relatively slow process
1. Mould fitting.
A fixed quantity of polymer in particle form is filled into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel material. The coloration preferred for the final product 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 engineering.
Preheating 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 placed within the oven.
2. The heat and fusion process.
Once within the oven, the mold is rotated on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The turning is done slowly and gradually, about 20 rotations per minute. One thing that is essential at this moment is the period of time the mould will spend inside the oven. If it stays to long, the product will lose stability and durability, making a faulty product. If it is extracted from the oven prematurely, the polymer will not have melted correctly, which produces bubbles in the finished 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 creates a cool mist. When the product cools, it reduces somewhat for ease of extraction from the mold. This is another step that relies a lot on the correct timing, since rapid cooling decreases the material too quickly, causing bending of the product.
4. The offloading or de-molding phase.
As soon as the component inside te mould has cooled properly, the person managing the procedure can then remove the finished product from the mold. The procedure is repeated from the start, providing a series of similar product lines.
For more information on the different rotational rotomolding options offered for the Hamden CT 6514 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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