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Rotational molding pertains to a plastic manufacturing procedure that makes hollow stress-free items. The procedure utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have many different designs, colors and sizes. This method is also referred to as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The function that makes this different from other plastic manufacturing procedures because no pressure is required. It also has few rivals when it pertains to the production of sizable hollow items which are long lasting and inexpensive.There is a variety of product lines that are produced by this process including large size water tanks, automobile items, complex molded medical items, recreation equipment, toys, canoes, commercial equipment among many others.This is due to the versatility in terms of style and forms that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Howe IN 46746, 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 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
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 Indiana 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 Howe Indiana 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 Roto-Molding Procedure in Detail
This molding method has been used since ancient times for creatingvseverl items. Egyptians for example, utilized rotomoulding systems in the making of ceramics. The Swiss were also working with this rotation format to generate hollow chocolate eggs. Some plastic items in the USA were made using this technique some time between 1940 and 1950. The technique has however taken long to take affect because it was considered to be a somewhat slow-moving process
1. Mold readying.
A fixed volume of polymer in powder form is packed into a hollow mold. The mold is usually composeded of cast aluminium or sheet steel component. The colour desired for the final product is pre compounded into the polymer. The most generally used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic manufacturing.
Pre-heating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mould with the powdered polymer is then secured and put into the oven.
2. The heating up and fusion phase.
Once inside the oven, the mold is rotated on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The rotation is done gradually, about 20 spins per minute. One thing that is essential at this moment is the period of time the mould will spend inside the oven. If it stays to long, the material will lose stability and durability, generating a faulty item. If it is removed from the oven prematurely, the polymer will not have melted properly, which develops bubbles in the completed item.
3. Mould cooling down.
When the material has completely spent the correct 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 generates a cool mist. When the material cools, it reduces a little for ease of extraction from the mold. This is an additional procedure that depends upon a lot on the right timing, since quick cooling decreases the material too quickly, causing bending of the item.
4. The removing or de-moulding step.
When the product inside te mold has cooled correctly, the molder handling the procedure can then take out the finished item from the mould. The technique is repeated from the start, making a series of similar items.
For more information on the different rotational rotomolding options offered for the Howe IN 46746 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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