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Rotational molding pertains to a plastic production solution that produces hollow stress-free products. The procedure relies upon high temperatures and bi axial rotation to follow up with seamless, one piece objects that have a wide range of shapes, sizes and colors. This method is also referred to 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 because no pressure is involved. It also has few rivals when it comes to the creation of large size hollow products which are long lasting and inexpensive.There is a wide range of items that are developed by this process including big water tanks, automobile items, intricate designed medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in terms of design and forms that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in East Marion NY 11939, 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 East Marion 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 operation has been used since early times for creatingvseverl items. Egyptians for example, worked with rotocasting methods in the creating of ceramics. The Swiss were also working with this rotation design to generate hollow chocolate eggs. Some plastic product lines in the USA were developed using this method some time between 1940 and 1950. Due to the fact that it was viewed to be a relatively slow system, the process has however taken long to catch on
1. Mold prep work.
A predetermined amount of polymer in powder form is packed into a hollow mold. The mould is usually comprised of cast aluminium or sheet steel component. The coloration preferred for the finished goods is pre compounded into the polymer. The most often 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 to temperatures between 500-700F. The mold with the powdered polymer is then sealed and inserted inside the oven.
2. The heating up and fusion step.
Once placed into the oven, the mold is rotated on two axis so the powdered polymer liquefies from the heat and layers the inside if the mold. The spinning is done slowly and gradually, about 20 spins per min. The main thing that is important at this moment is the period of time the mould will spend within the oven. If it overstays, the material will lose value and durability, creating a weak product. If it is removed from the oven prematurely, the polymer will not have liquefied correctly, which produces bubbles in the finalized item.
3. Mold cooling down.
When the component has sufficiently spent the right amount of time in the oven, it is then taken out 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 removal from the mold. This is an additional procedure that depends a lot on the right timing, since quick cooling decreases the material too quick, causing warping of the product.
4. The un-loading or de-moulding step.
As soon as the product within te mould has cooled successfully, the person managing the operation can then extract the finished item from the mold. The process is repeated from the start, making a number of identical product lines.
For more information on the different rotational molding options offered for the East Marion NY 11939 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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