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Rotational molding pertains to a plastic manufacturing solution that produces hollow stress-free products. The function relies upon high temperatures and bi axial rotation to come up with seamless, one piece products that have many different forms, sizes and colors. This method is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The component that makes this different from other plastic manufacturing processes that no pressure is needed. It also has few rivals when it comes to the production of large size hollow items which are resilient and inexpensive.There is a wide range of items that are generated by this process including large water tanks, automobile products, complex shaped medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in terms of type 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 Bethpage NY 11714, 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 Bethpage 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 Procedure in Detail
This moulding system has been used since ancient times for creatingvseverl products. Egyptians for instance, utilized roto-molding procedures in the of ceramics. The Swiss were also using this rotation format to create hollow chocolate eggs. Some plastic product lines in the USA were created utilizing this procedure some time between 1940 and 1950. Because it was considered to be a relatively slow system, the procedure has however taken long to catch on
1. Mould readying.
A predetermined volume of polymer in grain form is filled into a hollow mold. The mould is usually made from cast aluminium or sheet steel component. The color chosen for the end product is pre compounded into the polymer. The most generally used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic assembly.
Pre-heating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then sealed and inserted into the oven.
2. The heating up and fusion phase.
Once within the oven, the mold is spun on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The rotation is done slowly and gradually, about 20 revolutions per minute. Something that is crucial at this moment is the period of time the mold will spend inside the oven. If it overstays, the component will lose value and durability, making a faulty item. If it is removed from the oven too early, the polymer will not have flowed properly, which produces bubbles in the finalized product.
3. Mold cooling down.
When the component has sufficiently spent the correct 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 creates a cool mist. When the component cools, it reduces a little for ease of removal from the mold. This is an additional procedure that depends a lot on the correct timing, since quick cooling reduces the material too rapidly, causing bending of the item.
4. The unloading or de-molding step.
As soon as the product inside te mold has cooled effectively, the person taking care of the procedure can then take out the completed item from the mold. The procedure is repeated from the beginning, providing a number of similar product lines.
For more information on the different rotational molding options offered for the Bethpage NY 11714 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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