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Rotational moulding refers to a plastic manufacturing solution that generates hollow stress-free product lines. The function uses high temperatures and bi axial rotation to follow up with seamless, one piece objects that have a variety of forms, colors and sizes. This method is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The benefit that makes this unique from other plastic manufacturing methods because no pressure is needed. It also has few rivals when it comes down to the production of large size hollow products which are long-lasting and inexpensive.There is a variety of product lines that are produced by this process including big water tanks, automobile items, sophisticated designed medical products, recreation equipment, toys, kayaks, industrialized equipment among many others.This is because of the versatility 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 Elfers FL 34680, 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 rotational moulding 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 Florida 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 Elfers Florida 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 Procedure in Detail
This molding system has been used since earlier times for creatingvseverl items. Egyptians as an example, applied rotocasting procedures in the manufacturing of ceramics. The Swiss were also applying this rotation technique to make hollow chocolate eggs. Some plastic product lines in the USA were created using this technique some time between 1940 and 1950. Since it was considered to be a somewhat slow system, the procedure has however taken long to catch on
1. Mold prep work.
A predetermined measure of polymer in grain form is packed into a hollow mould. The mould is usually composeded of cast aluminium or sheet steel component. The color tone wanted for the final 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 manufacturing.
Preheating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then locked and inserted into the oven.
2. The heating and fusion procedure.
Once placed into the oven, the mold is spun on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The spinning is done gradually, about 20 spins per min. The main thing that is crucial at this moment is the amount of time the mould will spend within the oven. If it stays to long, the material will lose value and strength, creating a weak product. If it is extracted from the oven prematurely, the polymer will not have melted properly, which generates bubbles in the finished item.
3. Mould cooling.
When the product has sufficiently spent the right amount 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 slightly for ease of removal from the mould. This is yet another step that relies a lot on the correct timing, since quick cooling decreases the material too fast, causing bending of the material.
4. The discharging or de-moulding phase.
As soon as the material within te mould has cooled correctly, the person taking care of the process can then extract the completed product from the mould. The process is repeated from the start, giving a series of exact items.
For more information on the different rotational rotomolding options offered for the Elfers FL 34680 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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