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Rotational molding pertains to a plastic manufacturing method that produces hollow stress-free products. The process utilizes high temperatures and bi axial rotation to come up with seamless, one piece products that have various forms, sizes and colors. This technique is also referred to as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The attribute that makes this unique from other plastic manufacturing procedures because no pressure is called for. It also has few competitors when it involves the manufacture of large size hollow items which are long lasting and inexpensive.There is a wide variety of products that are developed by this process including large size water tanks, automobile items, intricate designed medical items, leisure equipment, toys, canoes, industrial equipment among many others.This is due to the versatility in regards to style and shapes that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Inver Grove Heights MN 55076, 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 Minnesota 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 Inver Grove Heights Minnesota 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 Method Components
This molding operation has been used since early times for creatingvseverl product lines. Egyptians for example, utilized roto-molding methods in the of ceramics. The Swiss were also making use of this rotation technique to create hollow chocolate eggs. Some plastic items in the USA were created using this procedure some time between 1940 and 1950. The procedure has however taken very long to take affect because it was considered as being a relatively slow-moving process
1. Mould fitting.
A predetermined quantity of polymer in particle form is packed into a hollow mold. The mold is usually comprised of cast aluminium or sheet steel component. The coloration preferred for the end goods 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 format of plastic manufacturing.
Pre-heating of the oven starts, and it can 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 sealed and positioned into the oven.
2. The heating up and fusion step.
Once within the oven, the mould is turned on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The spinning is done gradually, about 20 spins per sixty seconds. Something that is vital 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, creating a poor item. If it is taken out from the oven prematurely, the polymer will not have liquefied correctly, which produces bubbles in the completed product.
3. Mold cooling down.
When the component has completely spent the correct 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 material cools, it reduces somewhat for ease of removal from the mold. This is one more measure that depends upon a lot on the correct timing, since rapid cooling decreases the material too quick, causing warping of the material.
4. The unloading or de-moulding step.
As soon as the component inside te mold has cooled successfully, the molder handling the process can then take out the finished product from the mould. The technique is repeated from the start, providing a series of exact items.
For more information on the different rotational rotomolding options offered for the Inver Grove Heights MN 55076 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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