Looking for rotational molding alternatives in Illinois? Want affordable custom plastic molding that is cost effective for Downers Grove area? Then give us a call at our toll free number 866-971-7861 or request a quote today!

roto-molding-Downers Grove-Rotational moulding refers to a plastic manufacturing technique that generates hollow stress-free product lines. The process uses high temperatures and bi axial rotation to come up with seamless, one piece objects that have different shapes, sizes and colors. This technique is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.

The benefit that makes this different from other plastic manufacturing processes that no pressure is needed. It also has few rivals when it comes down to the manufacture of large size hollow products which are long lasting and inexpensive.There is a wide range of items that are created by this process including big water tanks, automobile materials, intricate designed medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is because of the flexibility in regards to style 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 Downers Grove IL 60515, 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

Custom Molding-Downers Grove-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 Illinois 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 Downers Grove Illinois 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 molding technique has been used since early times for creatingvseverl items. Egyptians for example, applied rotocasting systems in the manufacturing of ceramics. The Swiss were also applying this rotation format to make hollow chocolate eggs. Some plastic products in the USA were manufactured utilizing this approach some time between 1940 and 1950. Given that it was regarded to be a rather slow technique, the technique has however taken long to catch on

1. Mould prep work.
A fixed volume of polymer in grain form is packed into a hollow mold. The mould is usually made from cast aluminium or sheet steel material. The coloring needed for the end 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 style of plastic manufacturing.

Preheating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mould with the powdered polymer is then secured and positioned within the oven.

2. The heating up and fusion step.
Once inside the oven, the mould is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The spinning is done slowly, about 20 spins per sixty seconds. Something that is important at this moment is the period of time the mold will spend within the oven. If it overstays, the component will lose value and strength, generating a faulty product. If it is extracted from the oven too early, the polymer will not have melted properly, which generates bubbles in the finished item.

3. Mould cooling down.
When the product has sufficiently spent the enough 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 a cool mist. When the component cools, it reduces slightly for ease of extraction from the mold. This is yet another step that depends upon a lot on the correct timing, since quick cooling shrinks the material too fast, causing bending of the item.

4. The offloading or de-molding step.
As soon as the product inside te mould has cooled effectively, the molder managing the process can then remove the finished product from the mould. The procedure is repeated from the start, providing a series of similar items.

For more information on the different rotational molding options offered for the Downers Grove IL 60515 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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