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Rotational molding pertains to a plastic manufacturing practice that makes hollow stress-free product lines. The function uses high temperatures and bi axial rotation to follow up with seamless, one piece products that have a variety of shapes, sizes and colors. This technique is also known as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The feature that makes this unique from other plastic manufacturing procedures in that no pressure is required. It also has few competitors when it pertains to the production of large hollow products which are long lasting and inexpensive.There is a wide variety of products that are produced by this process including big water tanks, automobile products, intricate molded medical products, recreation equipment, toys, kayaks, industrialized equipment among many others.This is due to the flexibility 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 Auburn NY 13021, 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 rotational 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 Auburn 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 Procedure Components
This moulding process has been used since early times for creatingvseverl items. Egyptians for example, worked with rotational molding systems in the producing of ceramics. The Swiss were also making use of this rotation type to make hollow chocolate eggs. Some plastic product lines in the USA were created using this technique some time between 1940 and 1950. The system has however taken long to take affect because it was looked at as being a somewhat slow-moving process
1. Mould preparation.
A fixed amount of polymer in powder form is loaded into a hollow mold. The mould is usually made of cast aluminium or sheet steel substance. The color needed for the end goods 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 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 mould with the powdered polymer is then sealed and put into the oven.
2. The heating and fusion phase.
Once within the oven, the mould is spun on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The turning is done slowly and gradually, about 20 spins per minute. Something that is essential at this moment is the period of time the mold will spend inside the oven. If it overstays, the product will lose value and strength, producing a faulty product. If it is removed from the oven too early, the polymer will not have flowed correctly, which generates bubbles in the finished item.
3. Mold cooling down.
When the material has completely spent the right 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 generates a cool mist. When the material cools, it shrinks somewhat for ease of extraction from the mold. This is another procedure that depends a lot on the right timing, since rapid cooling shrinks the material too rapidly, causing bending of the product.
4. The removing or de-molding step.
As soon as the material inside te mold has cooled adequately, the molder taking care of the operation can then take out the finished product from the mold. The process is repeated from the beginning, giving a series of exact products.
For more information on the different rotational molding options offered for the Auburn NY 13021 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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