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Rotational molding refers to a plastic production method that creates hollow stress-free items. The process uses high temperatures and bi axial rotation to follow up with seamless, one piece items that have several designs, sizes and colors. This procedure is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The benefit that makes this unique from other plastic manufacturing processes in that no pressure is called for. It also has few competitors when it involves the production of large size hollow products which are long lasting and inexpensive.There is a variety of products that are produced by this process including big water tanks, automobile materials, complex molded medical items, recreation equipment, toys, canoes, commercial equipment among many others.This is because of the versatility in regards to type 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 Georgetown IL 61846, 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 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 Georgetown 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 Rotomoulding Process Components
This moulding procedure has been used since early times for creatingvseverl products. Egyptians for example, utilized rotomoulding techniques in the of ceramics. The Swiss were also making use of this rotation method to create hollow chocolate eggs. Some plastic products in the USA were developed utilizing this procedure some time between 1940 and 1950. The system has however taken long to take affect because it was thought of to be a somewhat slow process
1. Mold prep work.
A predetermined volume of polymer in powder form is loaded into a hollow mould. The mold is usually comprised of cast aluminium or sheet steel material. The coloration needed for the final product is pre compounded into the polymer. The most typically 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 to temperatures between 500-700F. The mould with the powdered polymer is then locked and put within the oven.
2. The heating up and fusion step.
Once placed into the oven, the mold is rotated on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The rotation is done slowly and gradually, about 20 rotations per sixty seconds. Something that is essential at this moment is the amount of time the mold will spend within the oven. If it overstays, the material will lose stability and strength, creating a weak item. If it is extracted from the oven too early, the polymer will not have flowed properly, which creates bubbles in the finished product line.
3. Mould cooling.
When the product has sufficiently spent the right amount 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 creates a cool mist. When the component cools, it shrinks slightly for ease of extraction from the mold. This is one more measure that depends upon a lot on the right timing, since rapid cooling shrinks the material too fast, causing bending of the item.
4. The discharging or de-molding step.
As soon as the material inside te mould has cooled effectively, the molder taking care of the process can then take out the finished product from the mould. The procedure is repeated from the beginning, making a number of similar product lines.
For more information on the different rotational molding options offered for the Georgetown IL 61846 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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