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Rotational molding refers to a plastic production solution that produces hollow stress-free product lines. The function relies on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have various designs, colors and sizes. This technique is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The component that makes this unique from other plastic manufacturing methods in that no pressure is needed. It also has few rivals when it comes to the manufacture of large size hollow items which are resilient and inexpensive.There is a wide variety of product lines that are produced by this process including large size water tanks, automobile items, sophisticated molded medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in regards to style and forms that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Lebanon IN 46052, 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 moulding 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 Lebanon 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 Rotomolding Process Components
This moulding process has been used since earlier times for creatingvseverl products. Egyptians for example, worked with rotational molding systems in the making of ceramics. The Swiss were also using this rotation method to generate hollow chocolate eggs. Some plastic items in the USA were made utilizing this method some time between 1940 and 1950. The process has however taken very long to take affect because it was thought of as being a rather slow-moving process
1. Mould preparation.
A fixed volume of polymer in particle form is loaded into a hollow mold. The mould is usually crafted from cast aluminium or sheet steel material. The coloration intended for the end item 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 design of plastic engineering.
Pre-heating 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 mold with the powdered polymer is then secured and inserted within the oven.
2. The heating and fusion step.
Once placed into the oven, the mold is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The turning is done gradually, about 20 rotations per sixty seconds. The main thing that is vital at this moment is the amount of time the mold will spend inside the oven. If it stays to long, the product will lose value and durability, creating a faulty item. If it is extracted from the oven too early, the polymer will not have melted properly, which generates bubbles in the finalized product.
3. Mold cooling.
When the product has completely spent the correct 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 generates a cool mist. When the product cools, it reduces slightly for ease of removal from the mould. This is an additional step that relies a lot on the correct timing, since rapid cooling decreases the material too fast, causing bending of the product.
4. The offloading or de-molding step.
When the product inside te mould has cooled effectively, the molder handling the operation can then extract the finished item from the mould. The function is repeated from the start, making a number of identical products.
For more information on the different rotational rotomolding options offered for the Lebanon IN 46052 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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