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Rotational molding pertains to a plastic manufacturing solution that makes hollow stress-free items. The function uses high temperatures and bi axial rotation to follow up with seamless, one piece items that have several shapes, sizes and colors. This technique is also known as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The function that makes this unique from other plastic manufacturing methods in that no pressure is involved. It also has few contenders when it comes down to the manufacture of large hollow products which are long-lasting and inexpensive.There is a variety of items that are generated by this process including large size water tanks, automobile items, intricate molded medical items, recreation equipment, toys, canoes, commercial equipment among many others.This is because of the flexibility in terms of design 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 New Washington IN 47162, 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 New Washington 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 Rotomoulding Method Components
This molding method has been used since early times for creatingvseverl items. Egyptians for instance, worked with rotocasting systems in the producing of ceramics. The Swiss were also working with this rotation technique to make hollow chocolate eggs. Some plastic items in the USA were manufactured using this approach some time between 1940 and 1950. Since it was viewed to be a fairly slow-moving process, the process has however taken long to catch on
1. Mould fitting.
A predetermined quantity of polymer in powder form is filled into a hollow mold. The mould is usually made from cast aluminium or sheet steel substance. The colour wanted 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 type of plastic engineering.
Pre-heating 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 mould with the powdered polymer is then secured and placed into the oven.
2. The heating up and fusion procedure.
Once within the oven, the mould is turned on two axis so the powdered polymer melts from the heat and coats the inside if the mold. The spinning is done gradually, about 20 rotations per minute. The main thing that is critical at this point is the amount of time the mould will spend within the oven. If it stays to long, the product will lose stability and durability, creating a poor product. If it is taken out from the oven prematurely, the polymer will not have melted properly, which develops bubbles in the finished product.
3. Mold cooling down.
When the material has sufficiently spent the enough of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which generates a cool mist. When the component cools, it shrinks somewhat for ease of removal from the mold. This is an additional measure that relies a lot on the correct timing, since rapid cooling reduces the material too quickly, causing warping of the item.
4. The removing or de-moulding phase.
Once the material inside te mold has cooled correctly, the person managing the operation can then take out the finished item from the mold. The technique is repeated from the beginning, providing a series of exact items.
For more information on the different rotational rotomolding options offered for the New Washington IN 47162 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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