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rotational molding-Bridgman-Rotational molding refers to a plastic manufacturing practice that makes hollow stress-free product lines. The technique relies upon high temperatures and bi axial rotation to follow up with seamless, one piece products that have several forms, sizes and colors. This technique is also known as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.

The attribute that makes this different from other plastic manufacturing techniques that no pressure is called for. It also has few contenders when it comes to the production of large size hollow products which are long-lasting and inexpensive.There is a wide variety of items that are developed by this process including big water tanks, automobile items, intricate shaped medical products, recreation equipment, toys, kayaks, industrialized equipment among many others.This is because of the flexibility in terms of design and shapes that the process develops

Benefits of Using Rotomolding to Manufacture Plastic Products

  • Relatively low tooling costs.
    When compared to other plastic manufacturing processes in Bridgman MI 49106, 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

Plastic Manufacturing-Bridgman-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 Michigan 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 Bridgman Michigan 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 Process Components

This moulding method has been used since early times for creatingvseverl products. Egyptians as an example, used rotomoulding systems in the making of ceramics. The Swiss were also making use of this rotation approach to generate hollow chocolate eggs. Some plastic products in the USA were made utilizing this technique some time between 1940 and 1950. The system has however taken very long to take affect because it was looked at as being a moderately slow-moving process

1. Mold preparation.
A fixed volume of polymer in grain form is filled into a hollow mold. The mould is usually composeded of cast aluminium or sheet steel component. The colour wanted for the end item is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this style of plastic assembly.

Pre-heating of the oven follows, and it can 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 sealed and positioned into the oven.

2. The heat and fusion process.
Once placed into the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The spinning is done slowly, about 20 spins per minute. Something that is critical at this moment is the amount of time the mould will spend inside the oven. If it stays to long, the product will lose value and durability, making a faulty item. If it is removed from the oven prematurely, the polymer will not have melted correctly, which produces bubbles in the finalized product line.

3. Mould cooling.
When the component has sufficiently spent the enough 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 a cool mist. When the material cools, it reduces a little for ease of extraction from the mold. This is yet another step that depends upon a lot on the right timing, since rapid cooling shrinks the material too quickly, causing warping of the item.

4. The offloading or de-moulding phase.
Once the component inside te mold has cooled successfully, the person handling the procedure can then remove the completed item from the mould. The function is repeated from the beginning, making a number of identical items.

For more information on the different rotational molding options offered for the Bridgman MI 49106, please call our toll free number  866-971-7861 or fill out the form on the right for a consultation!

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