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Rotational molding pertains to a plastic production technique that creates hollow stress-free product lines. The process utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have several designs, sizes and colors. This procedure is also referred to as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The benefit that makes this unique from other plastic manufacturing techniques that no pressure is involved. It also has few contenders when it comes to the creation of large hollow products which are long-lasting and inexpensive.There is a variety of items that are developed by this process including big water tanks, automobile materials, complex shaped medical items, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in regards to design and forms that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Dundalk MD 21222, 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 Maryland 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 Dundalk Maryland 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 process has been used since ancient times for creatingvseverl products. Egyptians for example, used rotational molding solutions in the creating of ceramics. The Swiss were also employing this rotation design to make hollow chocolate eggs. Some plastic products in the USA were made utilizing this technique some time between 1940 and 1950. The procedure has however taken very long to catch on because it was looked at as being a somewhat slow process
1. Mould readying.
A fixed measure of polymer in grain form is loaded into a hollow mold. The mold is usually crafted from cast aluminium or sheet steel material. The coloring intended for the end product is pre compounded into the polymer. The most typically used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this style of plastic engineering.
Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then secured and positioned within the oven.
2. The heat and fusion phase.
Once placed into the oven, the mold is revolved 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 spins per min. The main thing that is critical at this point is the amount of time the mold will spend within the oven. If it overstays, the material will lose stability and strength, making a weak item. If it is taken out from the oven prematurely, the polymer will not have melted properly, which creates bubbles in the finalized item.
3. Mould cooling down.
When the material has completely spent the correct amount of time in the oven, it is then taken out for cooling. This may be done by air or water, or sometimes a mixture of both which a cool mist. When the product cools, it reduces a little for ease of removal from the mold. This is yet another measure that depends upon a lot on the right timing, since quick cooling decreases the material too rapidly, causing bending of the item.
4. The discharging or de-molding step.
As soon as the component within te mould has cooled effectively, the molder managing the process can then remove the finished product from the mould. The process is repeated from the beginning, providing a number of similar products.
For more information on the different rotational rotomolding options offered for the Dundalk MD 21222 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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