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Rotational molding pertains to a plastic manufacturing solution that generates hollow stress-free product lines. The method relies upon high temperatures and bi axial rotation to come up with seamless, one piece objects that have different designs, colors and sizes. This method is also called rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The attribute that makes this different from other plastic manufacturing techniques in that no pressure is required. It also has few rivals when it involves the manufacture of large hollow products which are resilient and inexpensive.There is a wide variety of product lines that are produced by this process including large water tanks, automobile materials, complex molded medical items, leisure equipment, toys, kayaks, commercial equipment among many others.This is because of 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 Baldwinsville NY 13027, 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 Baldwinsville 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 Components
This molding procedure has been used since ancient times for creatingvseverl items. Egyptians for instance, utilized roto-molding methods in the manufacturing of ceramics. The Swiss were also applying this rotation approach to make hollow chocolate eggs. Some plastic products in the USA were manufactured utilizing this technique some time between 1940 and 1950. The procedure has however taken long to take affect because it was looked at as being a pretty slow process
1. Mould prep work.
A predetermined amount of polymer in powder form is loaded into a hollow mould. The mould is usually composeded of cast aluminium or sheet steel component. The color chosen 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 assembly.
Preheating of the oven follows, 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 sealed and put into the oven.
2. The heating up and fusion step.
Once within the oven, the mould is revolved on two axis so the powdered polymer liquefies from the heat and layers the inside if the mold. The rotation is done slowly, about 20 revolutions per min. One thing that is essential at this moment is the period of time the mold will spend within the oven. If it overstays, the material will lose value and durability, producing a poor product. If it is removed from the oven too early, the polymer will not have flowed correctly, which creates bubbles in the finished product line.
3. Mould cooling.
When the component has completely spent the correct amount of time in the oven, it is then taken out for cooling. This may be done by air or water, or sometimes a mixture of both which a cool mist. When the material cools, it reduces somewhat for ease of removal from the mold. This is an additional procedure that relies a lot on the correct timing, since quick cooling reduces the material too quickly, causing bending of the item.
4. The removing or de-molding step.
When the component inside te mould has cooled adequately, the molder handling the procedure can then remove the finished product from the mold. The process is repeated from the beginning, supplying a series of identical items.
For more information on the different rotational molding options offered for the Baldwinsville NY 13027 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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