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Rotational moulding pertains to a plastic manufacturing practice that produces hollow stress-free product lines. The technique relies on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have various forms, sizes and colors. This method is also called rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The attribute that makes this unique from other plastic manufacturing techniques because no pressure is required. It also has few rivals when it comes down to the creation of large size hollow items which are long lasting and inexpensive.There is a variety of products that are generated by this process including large size water tanks, automobile materials, intricate molded medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is due to the versatility in regards to design and forms that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Ages Brookside KY 40801, 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 Kentucky 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 Ages Brookside Kentucky 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 in Detail
This moulding system has been used since early times for creatingvseverl product lines. Egyptians as an example, utilized rotational molding systems in the of ceramics. The Swiss were also using this rotation format to generate hollow chocolate eggs. Some plastic products in the USA were created utilizing this technique some time between 1940 and 1950. The system has however taken very long to take affect because it was looked at to be a rather slow process
1. Mould preparation.
A predetermined volume of polymer in grain form is packed into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel substance. The coloration intended for the end goods 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 format of plastic assembly.
Pre-heating of the oven follows, 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 locked and positioned within the oven.
2. The heating and fusion procedure.
Once placed into the oven, the mould is spun on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The turning is done slowly and gradually, about 20 rotations per minute. Something that is vital at this moment is the period of time the mold will spend inside the oven. If it overstays, the product will lose stability and durability, generating a poor product. 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. Mold cooling down.
When the material has completely 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 creates a cool mist. When the product cools, it shrinks slightly for ease of extraction from the mold. This is an additional step that depends a lot on the ideal timing, since rapid cooling decreases the material too quickly, causing bending of the material.
4. The un-loading or de-molding step.
As soon as the material inside te mold has cooled effectively, the molder handling the process can then extract the finished product from the mould. The function is repeated from the beginning, supplying a series of identical items.
For more information on the different rotational molding options offered for the Ages Brookside KY 40801 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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