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Rotational moulding refers to a plastic production procedure that produces hollow stress-free items. The technique depends on high temperatures and bi axial rotation to follow up with seamless, one piece products that have varying shapes, colors and sizes. This technique is also known as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The attribute that makes this different from other plastic manufacturing processes in that no pressure is involved. It also has few contenders when it comes to the manufacture of sizable hollow items which are resilient and inexpensive.There is a variety of products that are produced by this process including large size water tanks, automobile products, sophisticated designed medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of style and forms that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Astoria NY 11102, 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 Astoria 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 Method in Detail
This molding procedure has been used since early times for creatingvseverl items. Egyptians for example, applied roto-molding techniques in the making of ceramics. The Swiss were also utilizing this rotation method to make hollow chocolate eggs. Some plastic product lines in the USA were created utilizing this approach some time between 1940 and 1950. Considering that it was considered to be a basically slow technique, the process has however taken long to become popular
1. Mold readying.
A predetermined measure of polymer in particle form is loaded into a hollow mould. The mold is usually composeded of cast aluminium or sheet steel component. The color preferred for the final product is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this type of plastic assembly.
Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mould with the powdered polymer is then sealed and installed into the oven.
2. The heating up and fusion procedure.
Once placed into the oven, the mould is spun on two axis so the powdered polymer liquefies from the heat and coats the inside if the mould. The spinning is done slowly and gradually, about 20 rotations 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 durability, producing a weak product. If it is taken out from the oven too early, the polymer will not have liquefied correctly, which generates bubbles in the finalized product line.
3. Mould cooling.
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 component cools, it reduces slightly for ease of extraction from the mould. This is another procedure that depends upon a lot on the right timing, since quick cooling reduces the material too fast, causing warping of the product.
4. The discharging or de-moulding phase.
Once the component inside te mould has cooled adequately, the molder handling the process can then remove the finished product from the mold. The procedure is repeated from the start, making a number of identical items.
For more information on the different rotational molding options offered for the Astoria NY 11102 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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