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Rotational molding refers to a plastic production technique that generates hollow stress-free product lines. The method utilizes high temperatures and bi axial rotation to come up with seamless, one piece objects that have a wide range of designs, colors and sizes. This technique is also referred to as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The attribute that makes this different from other plastic manufacturing procedures because no pressure is required. It also has few competitors when it comes down to the production of sizable hollow products which are long lasting and inexpensive.There is a variety of items that are created by this process including big water tanks, automobile items, sophisticated shaped medical items, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the flexibility in regards to design 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 Austerlitz NY 12017, 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 Austerlitz 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 molding method has been used since ancient times for creatingvseverl product lines. Egyptians for instance, applied rotocasting procedures in the making of ceramics. The Swiss were also utilizing this rotation method to generate hollow chocolate eggs. Some plastic products in the USA were created using this procedure some time between 1940 and 1950. The technique has however taken long to catch on because it was looked at to be a somewhat slow process
1. Mould fitting.
A fixed amount of polymer in grain form is packed into a hollow mould. The mould is usually composeded of cast aluminium or sheet steel material. The coloration preferred 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 format of plastic engineering.
Pre-heating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mould with the powdered polymer is then locked and placed within the oven.
2. The heating and fusion step.
Once within the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done gradually, about 20 revolutions per minute. Something that is crucial at this point is the amount of time the mould will spend inside the oven. If it overstays, the product will lose value and strength, making a faulty item. If it is taken out from the oven too early, the polymer will not have flowed properly, which develops bubbles in the completed product.
3. Mould cooling down.
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 product cools, it reduces somewhat for ease of removal from the mold. This is another step that depends a lot on the right timing, since rapid cooling shrinks the material too quickly, causing bending of the material.
4. The unloading or de-molding phase.
When the material inside te mold has cooled properly, the person handling the procedure can then remove the finalized product 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 Austerlitz NY 12017 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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