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

rotocasting-Mayfield-Rotational molding pertains to a plastic production technique that creates hollow stress-free items. The function uses high temperatures and bi axial rotation to come up with seamless, one piece products that have varying shapes, sizes and colors. This technique is also known 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 methods that no pressure is required. It also has few competitors when it comes down to the manufacture of large size hollow products which are resilient and inexpensive.There is a wide variety of items that are developed by this process including big water tanks, automobile materials, complex designed medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is because of the flexibility in regards to type and shapes that the process makes

Benefits of Using Rotomolding to Manufacture Plastic Products

  • Relatively low tooling costs.
    When compared to other plastic manufacturing processes in Mayfield KY 42066, 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

Plastic Manufacturing-Mayfield-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 Mayfield 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 procedure has been used since ancient times for creatingvseverl product lines. Egyptians for example, used rotocasting methods in the producing of ceramics. The Swiss were also employing this rotation method to generate hollow chocolate eggs. Some plastic items in the USA were made using this method some time between 1940 and 1950. Due to the fact that it was regarded to be a somewhat slow-moving approach, the system has however taken long to catch on

1. Mold preparation.
A predetermined quantity of polymer in powder form is filled into a hollow mould. The mould is usually built from cast aluminium or sheet steel substance. 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 format of plastic engineering.

Preheating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mould with the powdered polymer is then secured and placed into the oven.

2. The heating and fusion procedure.
Once inside the oven, the mold is spun on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The spinning is done gradually, about 20 spins per sixty seconds. The main thing that is essential at this moment is the period of time the mould will spend inside the oven. If it overstays, the material will lose value and strength, creating a weak product. If it is extracted from the oven prematurely, the polymer will not have melted properly, which generates bubbles in the finished product.

3. Mold cooling down.
When the product has completely spent the correct amount of time in the oven, it is then taken out for cooling. This can be done by air or water, or sometimes a mixture of both which creates a cool mist. When the product cools, it shrinks a little for ease of extraction from the mold. This is another procedure that depends a lot on the correct timing, since quick cooling reduces the material too fast, causing warping of the product.

4. The discharging or de-molding phase.
When the component within te mould has cooled successfully, the person handling the operation can then extract the completed item from the mould. The technique is repeated from the beginning, making a series of exact items.

For more information on the different rotational molding options offered for the Mayfield KY 42066 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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