Looking for rotational molding alternatives for New Jersey? Want affordable custom plastic molding that is cost effective for Mc Afee area? Then give us a call at our toll free number 866-971-7861 or request a quote today!
Rotational moulding refers to a plastic manufacturing method that generates hollow stress-free items. The method utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have varying designs, sizes and colors. This procedure is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The benefit that makes this unique from other plastic manufacturing techniques that no pressure is called for. It also has few rivals when it involves the production of large size hollow products which are long-lasting and inexpensive.There is a wide variety of product lines that are produced by this process including large size water tanks, automobile products, sophisticated molded medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is due to the flexibility in terms of style 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 Mc Afee NJ 7428, 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 rotomolding 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 Mc Afee 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 Rotomoulding Method Components
This molding technique has been used since ancient times for creatingvseverl products. Egyptians as an example, employed rotocasting procedures in the creating of ceramics. The Swiss were also applying this rotation method to generate hollow chocolate eggs. Some plastic products in the USA were made using this method some time between 1940 and 1950. Because it was viewed to be a very slow procedure, the approach has however taken long to catch on
1. Mold prep work.
A fixed amount of polymer in powder form is filled into a hollow mould. The mold is usually comprised of cast aluminium or sheet steel material. The coloring needed for the finished item is pre compounded into the polymer. The most generally used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this type of plastic manufacturing.
Preheating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then secured and positioned into the oven.
2. The heat and fusion procedure.
Once placed into the oven, the mold is revolved on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The turning is done slowly and gradually, about 20 rotations per minute. Something that is essential at this point is the amount of time the mold will spend inside the oven. If it overstays, the product will lose value and durability, making a weak product. If it is removed from the oven prematurely, the polymer will not have liquefied properly, which generates bubbles in the finished 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 creates a cool mist. When the product cools, it shrinks slightly for ease of removal from the mold. This is one more procedure that depends upon a lot on the ideal timing, since quick cooling decreases the material too rapidly, causing warping of the product.
4. The unloading or de-molding step.
As soon as the material inside te mould has cooled correctly, the molder managing the operation can then take out the finalized product from the mold. The function is repeated from the start, giving a series of similar product lines.
For more information on the different rotational rotomolding options offered for the Mc Afee NJ 7428 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
Other areas we service, go here to plastic molding