Looking for rotational molding alternatives in New York? Want affordable custom plastic molding that is cost effective for Bellerose area? Then give us a call at our toll free number 866-971-7861 or request a quote today!
Rotational moulding refers to a plastic manufacturing practice that generates hollow stress-free products. The process depends on high temperatures and bi axial rotation to follow up with seamless, one piece items that have a wide range of shapes, sizes and colors. This technique is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The function that makes this unique from other plastic manufacturing procedures in that no pressure is called for. It also has few rivals when it comes to the creation of large hollow items which are resilient and inexpensive.There is a variety of product lines that are produced by this process including big water tanks, automobile products, intricate shaped medical items, leisure equipment, toys, canoes, industrialized 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 Bellerose NY 11426, 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 rotomolding 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 Bellerose 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 method has been used since early times for creatingvseverl products. Egyptians for example, used rotocasting systems in the making of ceramics. The Swiss were also utilizing this rotation type to generate hollow chocolate eggs. Some plastic products in the USA were developed utilizing this procedure some time between 1940 and 1950. Given that it was thought of to be a relatively slow-moving approach, the process has however taken long to catch on
1. Mould prep work.
A fixed measure of polymer in particle form is filled into a hollow mold. The mold is usually constructed from cast aluminium or sheet steel material. The coloring preferred for the final 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 format of plastic assembly.
Preheating of the oven follows, and it may 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 secured and positioned inside the oven.
2. The heating and fusion process.
Once within the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and coats the inside if the mold. The spinning is done slowly and gradually, about 20 rotations per sixty seconds. The main thing that is crucial at this point is the period of time the mould will spend inside the oven. If it stays to long, the component will lose value and strength, producing a weak product. If it is extracted from the oven prematurely, the polymer will not have flowed properly, which produces bubbles in the finished product line.
3. Mold cooling.
When the product has completely spent the right amount 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 creates a cool mist. When the material cools, it shrinks a little for ease of removal from the mold. This is yet another step that relies a lot on the right timing, since quick cooling shrinks the material too quick, causing warping of the item.
4. The removing or de-molding phase.
As soon as the material within te mold has cooled successfully, the person managing the procedure can then extract the completed product from the mold. The process is repeated from the beginning, supplying a number of identical product lines.
For more information on the different rotational molding options offered for the Bellerose NY 11426 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
Other areas we service, go here to plastic manufacturing