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Rotational molding pertains to a plastic manufacturing solution that creates hollow stress-free product lines. The technique relies on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have several shapes, sizes and colors. This method is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The function that makes this different from other plastic manufacturing techniques in that no pressure is required. It also has few competitors when it comes to the creation of large size hollow products which are long-lasting and inexpensive.There is a wide range of items that are produced by this process including large size water tanks, automobile products, sophisticated molded medical items, leisure equipment, toys, kayaks, industrial equipment among many others.This is due to the versatility 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 Atlantic Highlands NJ 7716, 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 moulding 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 New Jersey 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 Atlantic Highlands New Jersey 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 Procedure in Detail
This moulding method has been used since earlier times for creatingvseverl product lines. Egyptians for example, worked with roto-molding systems in the of ceramics. The Swiss were also applying this rotation technique to make hollow chocolate eggs. Some plastic product lines in the USA were created utilizing this procedure some time between 1940 and 1950. Because it was viewed to be a fairly slow-moving technique, the process has however taken long to become popular
1. Mould preparation.
A predetermined volume of polymer in powder form is loaded into a hollow mold. The mold is usually crafted from cast aluminium or sheet steel material. The colour needed for the final item 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 type of plastic production.
Pre-heating of the oven follows, 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 locked and placed within the oven.
2. The heating up and fusion procedure.
Once placed into the oven, the mould is rotated on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done slowly and gradually, about 20 spins per sixty seconds. One thing that is critical at this point is the period of time the mold will spend within the oven. If it stays to long, the material will lose stability and strength, making a poor item. If it is taken out from the oven too early, the polymer will not have liquefied correctly, which generates bubbles in the completed item.
3. Mould cooling down.
When the material has completely spent the right 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 creates a cool mist. When the product cools, it reduces a little for ease of removal from the mould. This is yet another step that depends upon a lot on the correct timing, since quick cooling shrinks the material too quick, causing bending of the product.
4. The offloading or de-molding phase.
Once the component inside te mold has cooled adequately, the molder handling the procedure can then extract the completed product from the mold. The function is repeated from the beginning, making a number of identical items.
For more information on the different rotational rotomolding options offered for the Atlantic Highlands NJ 7716 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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