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Rotational moulding refers to a plastic manufacturing method that generates hollow stress-free products. The technique depends on high temperatures and bi axial rotation to follow up with seamless, one piece products that have many different forms, sizes and colors. This method is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The benefit that makes this unique from other plastic manufacturing methods in that no pressure is required. It also has few competitors when it comes to the production of large size hollow items which are long-lasting and inexpensive.There is a wide variety of product lines that are produced by this process including large size water tanks, automobile items, complex shaped medical items, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in regards to type and forms that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Lowville NY 13367, 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 rotomoulding 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 Lowville 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 Components
This moulding procedure has been used since early times for creatingvseverl items. Egyptians for example, utilized rotomoulding procedures in the creating of ceramics. The Swiss were also applying this rotation approach to make hollow chocolate eggs. Some plastic product lines in the USA were developed utilizing this method some time between 1940 and 1950. Since it was viewed to be a rather slow technique, the procedure has however taken long to catch on
1. Mold fitting.
A fixed quantity of polymer in grain form is packed into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel component. The coloration wanted for the finished 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 format of plastic manufacturing.
Pre-heating of the oven starts, 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 placed inside the oven.
2. The heating and fusion phase.
Once placed into the oven, the mold is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The spinning is done slowly, about 20 revolutions per sixty seconds. Something that is critical at this point is the amount of time the mould will spend inside the oven. If it overstays, the product will lose stability and strength, making a weak product. If it is taken out from the oven prematurely, the polymer will not have liquefied correctly, which creates bubbles in the finished product.
3. Mould cooling down.
When the material has completely spent the correct 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 creates a cool mist. When the component cools, it shrinks somewhat for ease of extraction from the mould. This is one more procedure that depends upon a lot on the right timing, since rapid cooling decreases the material too rapidly, causing bending of the item.
4. The unloading or de-molding phase.
As soon as the component within te mold has cooled adequately, the molder managing the process can then take out the completed product from the mold. The function is repeated from the beginning, providing a number of exact products.
For more information on the different rotational molding options offered for the Lowville NY 13367 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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