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Rotational molding pertains to a plastic manufacturing procedure that generates hollow stress-free product lines. The technique depends on high temperatures and bi axial rotation to come up with seamless, one piece items that have different forms, sizes and colors. This method is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The attribute that makes this unique from other plastic manufacturing methods because no pressure is needed. It also has few contenders when it comes down to the production of large size hollow items which are long-lasting and inexpensive.There is a wide variety of product lines that are generated 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 regards to type 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 South Berwick ME 3908, 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 South Berwick 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 molding system has been used since ancient times for creatingvseverl products. Egyptians for example, applied rotational molding techniques in the manufacturing of ceramics. The Swiss were also using this rotation method to make hollow chocolate eggs. Some plastic products in the USA were developed utilizing this method some time between 1940 and 1950. Given that it was considered to be a very slow-moving method, the approach has however taken long to become popular
1. Mould preparation.
A predetermined quantity of polymer in grain form is filled into a hollow mold. The mold is usually constructed from cast aluminium or sheet steel component. The color tone desired for the end 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 type of plastic assembly.
Pre-heating of the oven follows, 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 secured and installed into 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 liquefies from the heat and layers the inside if the mould. The turning is done slowly and gradually, about 20 spins per min. The main thing that is critical at this moment is the period of time the mold will spend within the oven. If it overstays, the component will lose stability and durability, making a weak item. If it is removed from the oven too early, the polymer will not have flowed properly, which develops bubbles in the finished 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 can be done by air or water, or sometimes a mixture of both which a cool mist. When the component cools, it reduces a little for ease of removal from the mould. This is one more measure that relies a lot on the ideal timing, since rapid cooling decreases the material too rapidly, causing warping of the material.
4. The offloading or de-molding step.
When the product inside te mold has cooled effectively, the person handling the operation can then extract the completed item from the mould. The process is repeated from the beginning, providing a number of similar items.
For more information on the different rotational rotomolding options offered for the South Berwick ME 3908 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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