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Rotational moulding refers to a plastic manufacturing method that makes hollow stress-free product lines. The process relies upon high temperatures and bi axial rotation to follow up with seamless, one piece items that have varying forms, colors and sizes. This procedure is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The feature that makes this different from other plastic manufacturing processes that no pressure is needed. It also has few contenders when it pertains to the production of large size hollow products which are long-lasting and inexpensive.There is a wide variety of items that are produced by this process including big water tanks, automobile products, sophisticated shaped medical items, recreation equipment, toys, canoes, industrial equipment among many others.This is due to the flexibility in terms of design and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Tower MN 55790, 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 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 Tower 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 Procedure in Detail
This moulding system has been used since early times for creatingvseverl products. Egyptians for instance, applied rotocasting systems in the producing of ceramics. The Swiss were also applying this rotation design to make hollow chocolate eggs. Some plastic product lines in the USA were manufactured utilizing this approach some time between 1940 and 1950. The procedure has however taken very long to take affect because it was looked at as being a pretty slow-moving process
1. Mold fitting.
A fixed volume of polymer in particle form is packed into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel substance. The coloring intended for the final product 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 design of plastic manufacturing.
Preheating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then secured and positioned inside the oven.
2. The heating and fusion phase.
Once placed into the oven, the mould is turned on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The rotation is done gradually, about 20 spins per min. One thing that is vital 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, producing a weak product. If it is taken out from the oven prematurely, the polymer will not have liquefied properly, which creates bubbles in the completed product line.
3. Mold cooling.
When the product has sufficiently spent the enough of time in the oven, it is then removed for cooling. This may be done by air or water, or sometimes a mixture of both which generates a cool mist. When the material cools, it reduces slightly for ease of removal from the mold. This is yet another procedure that relies a lot on the correct timing, since quick cooling reduces the material too fast, causing bending of the item.
4. The offloading or de-molding phase.
As soon as the component inside te mold has cooled adequately, the molder taking care of the procedure can then take out the finished item from the mould. The technique is repeated from the start, making a series of similar items.
For more information on the different rotational rotomolding options offered for the Tower MN 55790 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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