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Rotational molding pertains to a plastic manufacturing procedure that produces hollow stress-free products. The procedure depends on high temperatures and bi axial rotation to follow up with seamless, one piece products that have varying forms, sizes and colors. This procedure is also referred to as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The function that makes this unique from other plastic manufacturing procedures because no pressure is involved. It also has few contenders when it comes to the production of large size hollow products which are long lasting and inexpensive.There is a wide range of product lines that are generated by this process including large water tanks, automobile items, sophisticated molded medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the versatility in regards to design and shapes that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Franklin KS 66735, 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 rotomolding 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 Kansas 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 Franklin Kansas 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 Method Components
This molding process has been used since ancient times for creatingvseverl items. Egyptians as an example, worked with roto-molding techniques in the making of ceramics. The Swiss were also making use of this rotation style to make hollow chocolate eggs. Some plastic products in the USA were made utilizing this procedure some time between 1940 and 1950. The technique has however taken very long to take affect because it was considered to be a somewhat slow process
1. Mould prep work.
A fixed amount of polymer in particle form is packed into a hollow mold. The mould is usually made of cast aluminium or sheet steel material. The coloring intended for the end product 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 type of plastic manufacturing.
Pre-heating of the oven follows, and it can 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 locked and placed inside the oven.
2. The heating and fusion step.
Once within the oven, the mould is rotated on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The turning is done slowly and gradually, about 20 revolutions per min. The main thing that is crucial at this point is the period of time the mold will spend inside the oven. If it stays to long, the material will lose value and strength, producing a faulty product. If it is taken out from the oven too early, the polymer will not have liquefied correctly, which creates bubbles in the finished item.
3. Mold cooling.
When the product has sufficiently spent the right amount of time in the oven, it is then removed for cooling. This may be done by air or water, or sometimes a mixture of both which generates a cool mist. When the material cools, it reduces somewhat for ease of removal from the mould. This is one more measure that depends upon a lot on the correct timing, since rapid cooling shrinks the material too fast, causing warping of the item.
4. The removing or de-moulding phase.
When the material within te mould has cooled effectively, the person taking care of the operation can then extract the finalized product from the mold. The process is repeated from the beginning, providing a number of similar products.
For more information on the different rotational rotomolding options offered for the Franklin KS 66735 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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