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Rotational molding refers to a plastic production procedure that makes hollow stress-free items. The method relies on high temperatures and bi axial rotation to follow up with seamless, one piece products that have a wide range of forms, colors and sizes. This procedure is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The attribute that makes this unique from other plastic manufacturing techniques that no pressure is called for. It also has few contenders when it pertains to the creation of large size hollow products which are long lasting and inexpensive.There is a wide variety of product lines that are generated by this process including big water tanks, automobile items, intricate shaped medical products, leisure equipment, toys, canoes, industrial equipment among many others.This is due to the flexibility in regards to type and forms that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Ancram NY 12502, 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 Ancram 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 Rotomolding Process Components
This molding technique has been used since ancient times for creatingvseverl items. Egyptians as an example, utilized rotocasting systems in the creating of ceramics. The Swiss were also applying this rotation style to generate hollow chocolate eggs. Some plastic product lines in the USA were manufactured using this approach some time between 1940 and 1950. The process has however taken very long to catch on because it was looked at as being a rather slow-moving process
1. Mold fitting.
A fixed volume of polymer in powder form is loaded into a hollow mold. The mould is usually composeded of cast aluminium or sheet steel material. The coloration preferred for the finished product 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 manufacturing.
Pre-heating of the oven starts, 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 sealed and inserted inside the oven.
2. The heat and fusion step.
Once placed into the oven, the mould is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The rotation is done slowly, about 20 revolutions per min. 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 value and durability, generating a poor product. If it is removed from the oven prematurely, the polymer will not have melted properly, which generates bubbles in the finalized product line.
3. Mold cooling down.
When the component has sufficiently spent the correct amount of time in the oven, it is then taken out 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 a little for ease of removal from the mold. This is an additional measure that relies a lot on the right timing, since rapid cooling reduces the material too fast, causing bending of the product.
4. The offloading or de-moulding step.
When the material inside te mold has cooled properly, the person taking care of the operation can then take out the finalized item from the mold. The procedure is repeated from the beginning, giving a series of similar product lines.
For more information on the different rotational molding options offered for the Ancram NY 12502 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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