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Rotational moulding pertains to a plastic manufacturing method that produces hollow stress-free products. The process depends on high temperatures and bi axial rotation to come up with seamless, one piece products that have a wide range of forms, sizes and colors. This technique is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The feature that makes this unique from other plastic manufacturing techniques because no pressure is needed. It also has few rivals when it comes to the manufacture of large hollow items which are long lasting and inexpensive.There is a wide range of products that are generated by this process including large size water tanks, automobile materials, complex molded medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is due to 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 Scarborough ME 4070, 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
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 Scarborough 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 Roto-Molding Procedure in Detail
This moulding operation has been used since ancient times for creatingvseverl items. Egyptians for example, applied rotational molding solutions in the producing of ceramics. The Swiss were also using this rotation technique to create hollow chocolate eggs. Some plastic product lines in the USA were developed utilizing this approach some time between 1940 and 1950. Considering that it was thought of to be a basically slow procedure, the approach has however taken long to catch on
1. Mold prep work.
A fixed amount of polymer in grain form is loaded into a hollow mold. The mould is usually comprised of cast aluminium or sheet steel substance. The color tone desired for the finished item is pre compounded into the polymer. The most commonly used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this type of plastic manufacturing.
Preheating of the oven starts, and it may 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 locked and installed inside the oven.
2. The heating up and fusion phase.
Once inside the oven, the mold is turned on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The turning is done slowly, about 20 revolutions per sixty seconds. One thing that is important at this moment is the period of time the mould will spend inside the oven. If it stays to long, the product will lose value and durability, generating a poor product. If it is extracted from the oven too early, the polymer will not have flowed properly, which produces bubbles in the finished product line.
3. Mold cooling.
When the material has completely spent the enough of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the product cools, it shrinks a little for ease of extraction from the mould. This is an additional step that relies a lot on the correct timing, since quick cooling shrinks the material too quick, causing bending of the product.
4. The unloading or de-molding step.
As soon as the product within te mold has cooled adequately, the person handling the operation can then extract the completed item from the mold. The process is repeated from the start, supplying a series of exact products.
For more information on the different rotational rotomolding options offered for the Scarborough ME 4070 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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