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Rotational moulding refers to a plastic production method that produces hollow stress-free items. The method uses high temperatures and bi axial rotation to follow up with seamless, one piece items that have several forms, sizes and colors. This method is also known as 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 processes in that no pressure is called for. It also has few rivals when it comes to the production of large size hollow products which are long lasting and inexpensive.There is a wide variety of products that are developed by this process including large size water tanks, automobile products, intricate designed medical items, leisure equipment, toys, canoes, industrialized equipment among many others.This is due to the versatility in terms of design and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Bayside NY 11359, 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 moulding 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 Bayside 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 Rotomoulding Method Components
This molding technique has been used since ancient times for creatingvseverl products. Egyptians as an example, employed rotomoulding systems in the manufacturing of ceramics. The Swiss were also making use of this rotation technique to create hollow chocolate eggs. Some plastic product lines in the USA were developed utilizing this method some time between 1940 and 1950. Due to the fact that it was looked at to be a very slow system, the process has however taken long to catch on
1. Mould fitting.
A predetermined amount of polymer in particle form is filled into a hollow mold. The mold is usually comprised of cast aluminium or sheet steel material. The coloration preferred for the finished item is pre compounded into the polymer. The most typically used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic assembly.
Preheating 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 heat and fusion process.
Once within the oven, the mould is spun on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The rotation is done slowly and gradually, about 20 rotations per sixty seconds. The main thing that is important at this point is the amount of time the mold will spend inside the oven. If it overstays, the material will lose stability and durability, producing a poor product. If it is taken out from the oven too early, the polymer will not have flowed correctly, which generates bubbles in the completed item.
3. Mould cooling.
When the component 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 a cool mist. When the material cools, it shrinks slightly for ease of extraction from the mould. This is another procedure that depends upon a lot on the correct timing, since rapid cooling decreases the material too rapidly, causing warping of the product.
4. The unloading or de-moulding phase.
As soon as the material within te mould has cooled adequately, the person handling the process can then extract the completed product from the mold. The function is repeated from the start, supplying a number of similar products.
For more information on the different rotational molding options offered for the Bayside NY 11359 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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