Looking for rotational molding alternatives in Kentucky? Want affordable custom plastic molding that is cost effective for Calvert City area? Then give us a call at our toll free number 866-971-7861 or request a quote today!

rotomoulding-Calvert City-Rotational molding pertains to a plastic production method that makes hollow stress-free products. The method depends on high temperatures and bi axial rotation to follow up with seamless, one piece items that have varying designs, colors and sizes. This technique is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.

The feature that makes this unique from other plastic manufacturing methods in that no pressure is called for. It also has few competitors when it involves the manufacture of sizable hollow items which are long lasting and inexpensive.There is a variety of items that are developed by this process including large water tanks, automobile items, sophisticated shaped medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is because of the flexibility in terms of 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 Calvert City KY 42029, 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 rotocasting 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

Custom Molded-Calvert City-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 Calvert City 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 Rotomolding Process Components

This moulding operation has been used since earlier times for creatingvseverl product lines. Egyptians for example, worked with roto-molding procedures in the creating of ceramics. The Swiss were also working with this rotation design to generate hollow chocolate eggs. Some plastic products in the USA were manufactured utilizing this technique some time between 1940 and 1950. The system has however taken very long to catch on because it was looked at to be a very slow process

1. Mould readying.
A fixed amount of polymer in powder form is packed into a hollow mould. The mold is usually crafted from cast aluminium or sheet steel substance. The colour preferred 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 format of plastic manufacturing.

Pre-heating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then sealed and placed inside the oven.

2. The heating up and fusion phase.
Once placed into the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The rotation is done slowly and gradually, about 20 rotations per minute. One thing that is vital at this moment is the amount of time the mould will spend within the oven. If it overstays, the material will lose value and durability, making a weak product. If it is extracted from the oven prematurely, the polymer will not have melted properly, which develops bubbles in the finalized product line.

3. Mold cooling.
When the material has sufficiently spent the correct 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 material cools, it reduces somewhat for ease of removal from the mould. This is yet another procedure that depends a lot on the right timing, since quick cooling reduces the material too quick, causing warping of the item.

4. The offloading or de-molding phase.
Once the component within te mold has cooled adequately, the molder taking care of the process can then extract the finished product from the mold. The procedure is repeated from the start, making a number of exact product lines.

For more information on the different rotational molding options offered for the Calvert City KY 42029 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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