Looking for rotational molding alternatives in New York? Want affordable custom plastic molding that is cost effective for Alexander 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 procedure that makes hollow stress-free items. The method uses high temperatures and bi axial rotation to come up with seamless, one piece items that have many different forms, sizes and colors. This method is also referred to as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The benefit that makes this different from other plastic manufacturing procedures in that no pressure is required. It also has few rivals when it comes down to the creation of large size hollow products which are long-lasting and inexpensive.There is a wide variety of items that are created by this process including big water tanks, automobile materials, sophisticated molded medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is because of the versatility in regards to type and shapes that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Alexander NY 14005, 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 New York 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 Alexander New York 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 Roto-Molding Process in Detail
This moulding procedure has been used since ancient times for creatingvseverl product lines. Egyptians for example, applied rotomoulding procedures in the of ceramics. The Swiss were also making use of this rotation design to create hollow chocolate eggs. Some plastic items in the USA were made using this procedure some time between 1940 and 1950. Due to the fact that it was regarded to be a somewhat slow method, the method has however taken long to become popular
1. Mold prep work.
A predetermined volume of polymer in particle form is loaded into a hollow mould. The mould is usually composeded of cast aluminium or sheet steel material. The coloration wanted 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 format of plastic production.
Preheating of the oven follows, and it can 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 locked and inserted inside the oven.
2. The heating and fusion procedure.
Once placed into the oven, the mould is revolved 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 rotations per min. One thing that is crucial at this moment is the amount of time the mould will spend within the oven. If it overstays, the product will lose stability and durability, generating a weak product. If it is extracted from the oven prematurely, the polymer will not have flowed correctly, which generates bubbles in the completed item.
3. Mold cooling down.
When the product has sufficiently spent the enough 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 a cool mist. When the product cools, it shrinks slightly for ease of removal from the mould. This is another measure that depends upon a lot on the right timing, since quick cooling reduces the material too quickly, causing warping of the item.
4. The offloading or de-molding step.
When the product within te mould has cooled successfully, the molder handling the procedure can then extract the finished item from the mould. The process is repeated from the beginning, making a series of identical product lines.
For more information on the different rotational molding options offered for the Alexander NY 14005 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 manufacturing