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Rotational moulding pertains to a plastic manufacturing solution that makes hollow stress-free items. The method uses high temperatures and bi axial rotation to follow up with seamless, one piece objects that have varying shapes, colors and sizes. This technique is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The benefit that makes this unique from other plastic manufacturing processes that no pressure is needed. It also has few rivals when it comes to the production of large size hollow items which are resilient and inexpensive.There is a variety of product lines that are produced by this process including big water tanks, automobile items, sophisticated shaped medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in terms of type and shapes that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Vernon IN 47282, 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 rotomoulding 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 Vernon 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 Process Components
This molding process has been used since earlier times for creatingvseverl product lines. Egyptians for example, worked with rotocasting methods in the creating of ceramics. The Swiss were also working with this rotation technique to create hollow chocolate eggs. Some plastic items in the USA were made using this approach some time between 1940 and 1950. The technique has however taken very long to take affect because it was considered to be a moderately slow-moving process
1. Mould readying.
A predetermined quantity of polymer in powder form is loaded into a hollow mould. The mold is usually comprised of cast aluminium or sheet steel component. The color needed for the final goods 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 assembly.
Pre-heating 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 mould with the powdered polymer is then secured and put within the oven.
2. The heating and fusion step.
Once inside the oven, the mould is spun on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done slowly, about 20 revolutions per min. The main thing that is important at this point is the amount of time the mold will spend inside the oven. If it stays to long, the material will lose stability and strength, producing a faulty item. If it is removed from the oven too early, the polymer will not have melted properly, which creates bubbles in the finished product line.
3. Mould cooling down.
When the material has completely spent the correct amount 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 a cool mist. When the product cools, it shrinks somewhat for ease of removal from the mold. This is an additional procedure that depends upon a lot on the correct timing, since rapid cooling shrinks the material too fast, causing warping of the material.
4. The unloading or de-molding phase.
As soon as the component inside te mould has cooled adequately, the person handling the procedure can then remove the finalized product from the mold. The procedure is repeated from the beginning, providing a series of identical products.
For more information on the different rotational rotomolding options offered for the Vernon IN 47282 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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