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

rotocasting-Somerset-Rotational moulding pertains to a plastic manufacturing practice that makes hollow stress-free products. The procedure relies upon high temperatures and bi axial rotation to follow up with seamless, one piece items that have various shapes, colors and sizes. This procedure is also known as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.

The feature that makes this different from other plastic manufacturing techniques that no pressure is needed. It also has few contenders when it involves the production of large size hollow items which are long lasting and inexpensive.There is a wide variety of items that are created by this process including big water tanks, automobile products, sophisticated molded medical products, recreation equipment, toys, kayaks, industrial equipment among many others.This is due to the flexibility in regards to style and forms that the process develops

Benefits of Using Rotomolding to Manufacture Plastic Products

  • Relatively low tooling costs.
    When compared to other plastic manufacturing processes in Somerset KY 42501, 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 rotational moulding 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-Somerset-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 Somerset 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 Roto-Molding Procedure in Detail

This moulding operation has been used since early times for creatingvseverl items. Egyptians as an example, used rotocasting systems in the manufacturing of ceramics. The Swiss were also applying this rotation technique to make hollow chocolate eggs. Some plastic products in the USA were developed using this method some time between 1940 and 1950. Considering that it was regarded to be a very slow-moving method, the approach has however taken long to catch on

1. Mold prep work.
A fixed amount of polymer in powder form is packed into a hollow mold. The mold is usually made from cast aluminium or sheet steel material. The coloration preferred for the end product is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic assembly.

Pre-heating 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 mold with the powdered polymer is then sealed and installed into the oven.

2. The heat and fusion phase.
Once inside the oven, the mold is rotated on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The turning is done gradually, about 20 revolutions per sixty seconds. Something that is vital at this moment is the amount of time the mold will spend inside the oven. If it stays to long, the component will lose stability and durability, producing a weak item. If it is taken out from the oven prematurely, the polymer will not have melted properly, which generates bubbles in the finalized item.

3. Mold cooling.
When the material has completely spent the right amount of time in the oven, it is then extracted for cooling. This may be done by air or water, or sometimes a mixture of both which creates a cool mist. When the component cools, it shrinks somewhat for ease of removal from the mould. This is yet another procedure that depends a lot on the correct timing, since quick cooling shrinks the material too quickly, causing warping of the product.

4. The un-loading or de-moulding phase.
When the product within te mould has cooled properly, the molder taking care of the procedure can then remove the finished product from the mould. The procedure is repeated from the beginning, giving a series of similar items.

For more information on the different rotational molding options offered for the Somerset KY 42501 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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