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Rotational molding refers to a plastic manufacturing method that generates hollow stress-free products. The procedure relies on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have a wide range of shapes, colors and sizes. This method is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The benefit that makes this different from other plastic manufacturing procedures in that no pressure is needed. It also has few contenders when it involves the production of sizable hollow products which are long lasting and inexpensive.There is a variety of items that are created by this process including large size water tanks, automobile items, sophisticated molded medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of design and forms that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Benton MO 63736, 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 rotational 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 Missouri 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 Benton Missouri 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 molding operation has been used since ancient times for creatingvseverl products. Egyptians for example, utilized rotational molding techniques in the producing of ceramics. The Swiss were also employing this rotation type to generate hollow chocolate eggs. Some plastic product lines in the USA were made using this technique some time between 1940 and 1950. Since it was thought of to be a rather slow system, the method has however taken long to catch on
1. Mold prep work.
A predetermined measure of polymer in particle form is packed into a hollow mold. The mould is usually made of cast aluminium or sheet steel substance. The coloration desired for the end 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 type of plastic production.
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 mold with the powdered polymer is then secured and installed within the oven.
2. The heating and fusion phase.
Once placed into the oven, the mould is turned on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The spinning is done gradually, about 20 spins per min. One thing that is important at this moment is the period of time the mould will spend within the oven. If it overstays, the product will lose value and durability, generating a weak product. If it is extracted from the oven prematurely, the polymer will not have liquefied properly, which generates bubbles in the finished item.
3. Mold cooling down.
When the product has sufficiently spent the enough of time in the oven, it is then removed 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 yet another procedure that depends upon a lot on the correct timing, since quick cooling decreases the material too rapidly, causing bending of the item.
4. The discharging or de-moulding phase.
As soon as the component inside te mold has cooled properly, the person handling the procedure can then take out the finalized item from the mould. The procedure is repeated from the start, providing a series of similar product lines.
For more information on the different rotational molding options offered for the Benton MO 63736 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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