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Rotational molding refers to a plastic production procedure that produces hollow stress-free products. The technique utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have a wide range of designs, sizes and colors. This technique is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The benefit that makes this unique from other plastic manufacturing processes because no pressure is involved. It also has few competitors when it involves the production of large hollow items which are long lasting and inexpensive.There is a wide range of product lines that are created by this process including big water tanks, automobile materials, sophisticated shaped medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is because of the versatility in regards to style 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 Owls Head ME 4854, 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 rotomoulding 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 Maine 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 Owls Head Maine 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 in Detail
This moulding system has been used since early times for creatingvseverl items. Egyptians as an example, used rotational molding procedures in the manufacturing of ceramics. The Swiss were also using this rotation technique to make hollow chocolate eggs. Some plastic items in the USA were developed using this approach some time between 1940 and 1950. The system has however taken long to catch on because it was considered to be a pretty slow process
1. Mould preparation.
A predetermined quantity of polymer in particle form is loaded into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel substance. The color tone preferred for the finished item 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 design of plastic production.
Preheating 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 put within the oven.
2. The heat and fusion phase.
Once within the oven, the mould is turned on two axis so the powdered polymer liquefies from the heat and coats the inside if the mold. The turning is done slowly and gradually, about 20 revolutions per sixty seconds. The main thing that is crucial at this point is the amount of time the mold will spend inside the oven. If it stays to long, the material will lose value and strength, creating a weak product. If it is removed from the oven too early, the polymer will not have melted properly, which generates bubbles in the completed product line.
3. Mold cooling down.
When the material has completely spent the right 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 material cools, it reduces slightly for ease of extraction from the mold. This is one more step that depends upon a lot on the correct timing, since quick cooling reduces the material too quick, causing warping of the product.
4. The removing or de-moulding phase.
When the product inside te mold has cooled successfully, the person taking care of the operation can then remove the completed item from the mould. The procedure is repeated from the beginning, giving a series of similar items.
For more information on the different rotational rotomolding options offered for the Owls Head ME 4854 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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