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Rotational molding pertains to a plastic production technique that produces hollow stress-free product lines. The method uses high temperatures and bi axial rotation to come up with seamless, one piece objects that have a variety of designs, sizes and colors. This method is also called rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The attribute that makes this unique from other plastic manufacturing processes that no pressure is needed. It also has few rivals when it comes down to the manufacture of large hollow products which are long lasting and inexpensive.There is a variety of products that are produced by this process including big water tanks, automobile products, sophisticated shaped medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the versatility in regards to style and forms that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Middle River MD 21220, 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 rotomolding 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 Middle River 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 Roto-Molding Method Components
This moulding operation has been used since earlier times for creatingvseverl products. Egyptians as an example, worked with roto-molding techniques in the making of ceramics. The Swiss were also utilizing this rotation method to make hollow chocolate eggs. Some plastic products in the USA were manufactured using this approach some time between 1940 and 1950. Because it was looked at to be a basically slow-moving method, the process has however taken long to catch on
1. Mould preparation.
A fixed volume of polymer in grain form is packed into a hollow mold. The mold is usually constructed from cast aluminium or sheet steel component. The color tone wanted for the final 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 format of plastic assembly.
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 mould with the powdered polymer is then locked and placed inside the oven.
2. The heating and fusion phase.
Once inside the oven, the mould is spun on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The turning is done gradually, about 20 revolutions per min. Something that is critical at this moment is the amount of time the mold will spend inside the oven. If it overstays, the product will lose value and strength, producing a poor item. If it is removed from the oven prematurely, the polymer will not have liquefied properly, which creates bubbles in the finished product.
3. Mould cooling down.
When the product has sufficiently spent the enough 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 material cools, it shrinks somewhat for ease of extraction from the mold. This is one more step that depends a lot on the right timing, since quick cooling reduces the material too quick, causing warping of the material.
4. The discharging or de-molding step.
When the product within te mould has cooled effectively, the person handling the procedure can then remove the completed product from the mould. The technique is repeated from the beginning, supplying a number of exact products.
For more information on the different rotational rotomolding options offered for the Middle River MD 21220 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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