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rotational moulding-Madison-Rotational moulding refers to a plastic manufacturing technique that generates hollow stress-free product lines. The technique relies upon high temperatures and bi axial rotation to come up with seamless, one piece items that have various designs, colors and sizes. This procedure is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.

The component that makes this different from other plastic manufacturing procedures that no pressure is required. It also has few competitors when it comes down to the manufacture of large size hollow items which are long-lasting and inexpensive.There is a wide range of items that are produced by this process including large size water tanks, automobile items, intricate designed medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is because of the versatility 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 Madison IL 62060, 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 Products-Madison-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 Madison 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 in Detail

This moulding operation has been used since ancient times for creatingvseverl product lines. Egyptians for instance, employed rotational molding solutions in the of ceramics. The Swiss were also using this rotation design to make hollow chocolate eggs. Some plastic products in the USA were developed using this procedure some time between 1940 and 1950. The procedure has however taken long to catch on because it was thought of as being a somewhat slow-moving process

1. Mold prep work.
A fixed amount of polymer in powder form is loaded into a hollow mould. The mold is usually built from cast aluminium or sheet steel substance. The color tone desired for the end goods 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 design of plastic manufacturing.

Preheating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then sealed and placed inside the oven.

2. The heat and fusion process.
Once inside the oven, the mould is revolved 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 spins per sixty seconds. One thing that is important at this moment is the amount of time the mold will spend within the oven. If it stays to long, the component will lose value and strength, generating a faulty product. If it is taken out from the oven prematurely, the polymer will not have flowed correctly, which develops bubbles in the completed item.

3. Mould cooling.
When the component 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 product cools, it shrinks slightly for ease of extraction from the mold. This is yet another procedure that relies a lot on the correct timing, since rapid cooling shrinks the material too fast, causing bending of the material.

4. The unloading or de-molding step.
As soon as the product inside te mold has cooled properly, the molder taking care of the procedure can then take out the finished item from the mold. The technique is repeated from the beginning, giving a number of similar items.

For more information on the different rotational molding options offered for the Madison IL 62060 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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