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Rotational molding refers to a plastic production method that generates hollow stress-free products. The method depends on high temperatures and bi axial rotation to follow up with seamless, one piece items that have different shapes, sizes and colors. This procedure is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The attribute that makes this unique from other plastic manufacturing procedures that no pressure is involved. It also has few rivals when it comes to the manufacture of sizable hollow items which are resilient and inexpensive.There is a wide range of products that are produced by this process including big water tanks, automobile products, intricate shaped medical items, recreation equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in regards to 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 Comstock NY 12821, 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 Comstock 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 molding technique has been used since earlier times for creatingvseverl items. Egyptians for example, worked with roto-molding methods in the creating of ceramics. The Swiss were also working with this rotation design to make hollow chocolate eggs. Some plastic product lines in the USA were developed utilizing this procedure some time between 1940 and 1950. Due to the fact that it was thought of to be a somewhat slow-moving approach, the process has however taken long to catch on
1. Mold fitting.
A predetermined measure of polymer in particle form is packed into a hollow mould. The mould is usually made of cast aluminium or sheet steel substance. The color tone chosen 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 manufacturing.
Preheating 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 mould with the powdered polymer is then secured and put into the oven.
2. The heating and fusion process.
Once inside the oven, the mold is turned on two axis so the powdered polymer liquefies from the heat and coats the inside if the mold. The spinning is done slowly, about 20 revolutions per minute. The main thing that is crucial at this point is the period of time the mould will spend within the oven. If it overstays, the material will lose stability and durability, generating a weak item. If it is removed from the oven prematurely, the polymer will not have melted correctly, which creates bubbles in the completed item.
3. Mold cooling down.
When the material has sufficiently spent the enough 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 creates a cool mist. When the material cools, it reduces a little for ease of extraction from the mould. This is an additional step that depends upon a lot on the right timing, since rapid cooling shrinks the material too quick, causing warping of the material.
4. The unloading or de-molding phase.
Once the component within te mould has cooled adequately, the person managing the operation can then remove the finished product from the mould. The function is repeated from the beginning, providing a series of similar product lines.
For more information on the different rotational molding options offered for the Comstock NY 12821 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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