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Rotational molding pertains to a plastic manufacturing procedure that generates hollow stress-free items. The process relies upon high temperatures and bi axial rotation to follow up with seamless, one piece products that have a variety of designs, sizes and colors. This technique is also referred to as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The function that makes this different from other plastic manufacturing procedures because no pressure is involved. It also has few contenders when it comes down to the creation of large size hollow items which are long lasting and inexpensive.There is a wide range of products that are developed by this process including large water tanks, automobile items, sophisticated shaped medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is because of the flexibility in regards to style 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 Chappaqua NY 10514, 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 Chappaqua 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 Rotomolding Process in Detail
This moulding system has been used since earlier times for creatingvseverl products. Egyptians for instance, worked with rotocasting solutions in the producing of ceramics. The Swiss were also working with this rotation format to make hollow chocolate eggs. Some plastic items in the USA were developed using this method some time between 1940 and 1950. The technique has however taken very long to catch on because it was looked at to be a somewhat slow-moving process
1. Mould prep work.
A fixed amount of polymer in particle form is loaded into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel component. The coloration preferred for the final goods 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 follows, and it can be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mold with the powdered polymer is then secured and put within the oven.
2. The heat and fusion phase.
Once within the oven, the mould is spun on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The turning is done gradually, about 20 revolutions per minute. Something that is important at this point is the amount of time the mold will spend within the oven. If it overstays, the component will lose stability and strength, generating a faulty item. If it is extracted from the oven too early, the polymer will not have melted correctly, which creates bubbles in the finalized product line.
3. Mould cooling down.
When the component has sufficiently spent the right amount of time in the oven, it is then removed 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 shrinks a little for ease of extraction from the mold. This is one more measure that depends a lot on the right timing, since rapid cooling decreases the material too fast, causing warping of the product.
4. The offloading or de-moulding phase.
Once the product inside te mold has cooled properly, the person taking care of the operation can then take out the finalized product from the mold. The procedure is repeated from the beginning, supplying a series of identical products.
For more information on the different rotational molding options offered for the Chappaqua NY 10514 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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