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Rotational moulding refers to a plastic manufacturing practice that makes hollow stress-free products. The process utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have a variety of designs, sizes and colors. This technique is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The component that makes this different from other plastic manufacturing procedures because no pressure is called for. It also has few contenders when it comes to the creation of sizable hollow products which are resilient and inexpensive.There is a wide range of items that are produced by this process including large size water tanks, automobile products, sophisticated designed medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is due to the flexibility in regards to style and shapes that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Lagrangeville NY 12540, 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 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 Lagrangeville 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 Method in Detail
This moulding process has been used since ancient times for creatingvseverl products. Egyptians for example, employed rotomoulding techniques in the making of ceramics. The Swiss were also making use of this rotation approach to make hollow chocolate eggs. Some plastic product lines in the USA were manufactured utilizing this method some time between 1940 and 1950. Due to the fact that it was looked at to be a very slow-moving method, the method has however taken long to catch on
1. Mould fitting.
A fixed volume of polymer in powder form is filled into a hollow mold. The mold is usually built from cast aluminium or sheet steel material. The color tone preferred for the end item 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 production.
Pre-heating of the oven follows, and it can 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 installed into the oven.
2. The heat and fusion procedure.
Once placed into the oven, the mold is turned on two axis so the powdered polymer liquefies from the heat and coats the inside if the mould. The turning is done gradually, about 20 rotations per minute. One thing that is crucial at this moment is the amount of time the mold will spend within the oven. If it stays to long, the component will lose value and durability, creating a faulty product. If it is extracted from the oven too early, the polymer will not have liquefied correctly, which develops bubbles in the finished product.
3. Mold cooling down.
When the material has completely 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 a cool mist. When the product cools, it reduces a little for ease of removal from the mould. This is one more measure that relies a lot on the ideal timing, since quick cooling decreases the material too quickly, causing bending of the product.
4. The removing or de-molding step.
Once the product within te mold has cooled adequately, the molder managing the process can then take out the completed item from the mold. The function is repeated from the start, making a series of identical product lines.
For more information on the different rotational molding options offered for the Lagrangeville NY 12540 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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