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

rotocasting-Lyons-Rotational moulding pertains to a plastic production method that produces hollow stress-free products. The process uses high temperatures and bi axial rotation to follow up with seamless, one piece products that have several designs, colors and sizes. This method is also referred to 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 because no pressure is required. It also has few contenders when it comes down to the production of sizable hollow items which are resilient and inexpensive.There is a variety of product lines that are generated by this process including large size water tanks, automobile materials, intricate molded medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of 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 Lyons IL 60534, 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

Plastic Manufacturing-Lyons-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 Lyons 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 Procedure Components

This moulding process has been used since ancient times for creatingvseverl items. Egyptians for example, employed rotomoulding systems in the of ceramics. The Swiss were also working with this rotation approach to generate hollow chocolate eggs. Some plastic product lines in the USA were made using this procedure some time between 1940 and 1950. Because it was looked at to be a fairly slow method, the technique has however taken long to become popular

1. Mould fitting.
A predetermined volume of polymer in powder form is loaded into a hollow mould. The mold is usually constructed from cast aluminium or sheet steel substance. The color wanted for the finished item is pre compounded into the polymer. The most commonly used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic assembly.

Preheating of the oven follows, 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 locked and put inside the oven.

2. The heating and fusion phase.
Once within the oven, the mould is rotated on two axis so the powdered polymer melts from the heat and coats the inside if the mold. The rotation is done slowly, about 20 revolutions per minute. Something that is important at this moment is the amount of time the mold will spend inside the oven. If it overstays, the product will lose stability and durability, generating a poor product. If it is taken out from the oven too early, the polymer will not have liquefied correctly, which creates bubbles in the finished product.

3. Mould cooling down.
When the material has sufficiently spent the correct amount of time in the oven, it is then extracted for cooling. This can be done by air or water, or sometimes a mixture of both which generates a cool mist. When the material cools, it shrinks slightly for ease of removal from the mold. This is yet another step that relies a lot on the correct timing, since quick cooling decreases the material too quick, causing bending of the product.

4. The discharging or de-molding step.
As soon as the component inside te mould has cooled properly, the molder taking care of the operation can then remove the finished item from the mould. The procedure is repeated from the beginning, making a series of identical products.

For more information on the different rotational molding options offered for the Lyons IL 60534 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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