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Rotational molding pertains to a plastic manufacturing practice that makes hollow stress-free products. The procedure utilizes high temperatures and bi axial rotation to follow up with seamless, one piece objects that have varying shapes, sizes and colors. This method is also referred to as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The attribute that makes this different from other plastic manufacturing processes that no pressure is involved. It also has few rivals when it pertains to the production of large hollow items which are long-lasting and inexpensive.There is a wide variety of products that are generated by this process including large water tanks, automobile materials, sophisticated designed medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of type 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 Minneola KS 67865, 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 roto-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 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 Minneola 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 Rotomolding Procedure in Detail
This moulding operation has been used since early times for creatingvseverl products. Egyptians as an example, utilized rotocasting solutions in the producing of ceramics. The Swiss were also employing this rotation type to create hollow chocolate eggs. Some plastic product lines in the USA were created using this method some time between 1940 and 1950. The technique has however taken long to take affect because it was looked at to be a somewhat slow-moving process
1. Mold prep work.
A fixed measure of polymer in powder form is filled into a hollow mold. The mold is usually made from cast aluminium or sheet steel component. The color tone wanted for the end product is pre compounded into the polymer. The most commonly 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 starts, and it may be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mold with the powdered polymer is then sealed and placed within the oven.
2. The heating and fusion phase.
Once placed into the oven, the mold is spun on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The rotation is done gradually, about 20 rotations per minute. One thing that is essential at this point is the amount of time the mold will spend within the oven. If it overstays, the component will lose value and strength, producing a poor item. If it is removed from the oven too early, the polymer will not have liquefied correctly, which generates bubbles in the finalized product.
3. Mould cooling down.
When the material has completely spent the enough of time in the oven, it is then extracted for cooling. This can be done by air or water, or sometimes a mixture of both which creates a cool mist. When the material cools, it reduces a little for ease of removal from the mould. This is another measure that relies a lot on the correct timing, since quick cooling reduces the material too quickly, causing warping of the material.
4. The offloading or de-moulding step.
As soon as the material inside te mold has cooled successfully, the person managing the procedure can then take out the completed item from the mould. The function is repeated from the start, providing a series of similar product lines.
For more information on the different rotational rotomolding options offered for the Minneola KS 67865 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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