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Rotational molding pertains to a plastic production method that creates hollow stress-free product lines. The method utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have various forms, sizes and colors. This procedure is also referred to as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The function that makes this different from other plastic manufacturing techniques in that no pressure is required. It also has few competitors when it pertains to the manufacture of sizable hollow items which are long-lasting and inexpensive.There is a variety of product lines that are developed by this process including large size water tanks, automobile materials, intricate shaped medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of design and shapes that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Prinsburg MN 56281, 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 roto-molding 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 Prinsburg 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 Rotomoulding Method Components
This moulding system has been used since ancient times for creatingvseverl product lines. Egyptians for example, used roto-molding techniques in the producing of ceramics. The Swiss were also working with this rotation method to make hollow chocolate eggs. Some plastic products in the USA were created utilizing this procedure some time between 1940 and 1950. The process has however taken very long to catch on because it was considered as being a moderately slow process
1. Mold fitting.
A predetermined measure of polymer in particle form is filled into a hollow mold. The mould is usually constructed from cast aluminium or sheet steel component. The color tone desired for the finished 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 design of plastic production.
Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mould with the powdered polymer is then sealed and installed into the oven.
2. The heating and fusion step.
Once within the oven, the mold is rotated on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The rotation is done gradually, about 20 revolutions per sixty seconds. Something that is critical at this moment is the period of time the mould will spend within the oven. If it overstays, the product will lose stability and durability, generating a faulty item. If it is taken out from the oven too early, the polymer will not have flowed correctly, which produces bubbles in the finalized item.
3. Mould cooling down.
When the product has sufficiently spent the correct amount 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 generates a cool mist. When the product cools, it shrinks a little for ease of removal from the mold. This is yet another procedure that relies a lot on the ideal timing, since quick cooling reduces the material too fast, causing bending of the product.
4. The removing or de-moulding phase.
As soon as the product inside te mould has cooled correctly, the person managing the process can then take out the finished product from the mold. The procedure is repeated from the start, supplying a number of identical products.
For more information on the different rotational rotomolding options offered for the Prinsburg MN 56281 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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