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Rotational molding refers to a plastic production solution that creates hollow stress-free items. The process utilizes high temperatures and bi axial rotation to follow up with seamless, one piece items that have varying shapes, colors and sizes. This procedure is also referred to as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The feature 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 creation of sizable hollow products which are durable and inexpensive.There is a wide range of product lines that are generated by this process including big water tanks, automobile products, intricate shaped medical items, leisure equipment, toys, canoes, industrial equipment among many others.This is because of the versatility in regards to style and shapes that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Athens NY 12015, 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 rotomoulding 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 Athens 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 Procedure in Detail
This moulding process has been used since early times for creatingvseverl products. Egyptians as an example, applied rotomoulding systems in the making of ceramics. The Swiss were also employing this rotation approach to make hollow chocolate eggs. Some plastic products in the USA were developed utilizing this approach some time between 1940 and 1950. Since it was thought of to be a fairly slow-moving process, the system has however taken long to catch on
1. Mold preparation.
A fixed measure of polymer in powder form is filled into a hollow mold. The mould is usually constructed from cast aluminium or sheet steel component. The color wanted for the finished 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 design of plastic engineering.
Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mould with the powdered polymer is then sealed and placed into the oven.
2. The heating up and fusion phase.
Once inside 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 turning is done slowly and gradually, about 20 rotations per sixty seconds. Something that is crucial at this moment is the amount of time the mold will spend within the oven. If it stays to long, the component will lose value and strength, generating a poor product. If it is extracted from the oven too early, the polymer will not have flowed correctly, which generates bubbles in the finished product line.
3. Mould cooling.
When the material has completely 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 generates a cool mist. When the component cools, it reduces a little for ease of removal from the mold. This is another measure that depends a lot on the correct timing, since quick cooling shrinks the material too fast, causing warping of the material.
4. The offloading or de-molding phase.
When the product inside te mold has cooled successfully, the person taking care of the operation can then extract the completed product from the mould. The procedure is repeated from the beginning, providing a number of similar products.
For more information on the different rotational molding options offered for the Athens NY 12015 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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