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Rotational moulding pertains to a plastic production procedure that creates hollow stress-free products. The technique relies on high temperatures and bi axial rotation to follow up with seamless, one piece objects that have varying designs, sizes and colors. This procedure is also referred to as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The feature that makes this different from other plastic manufacturing techniques in that no pressure is required. It also has few competitors when it comes to the creation of large size hollow products which are long lasting and inexpensive.There is a wide variety of items that are generated by this process including big water tanks, automobile materials, intricate shaped medical items, recreation equipment, toys, kayaks, industrial equipment among many others.This is because of the flexibility in regards to design and shapes that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Marlboro NY 12542, 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 Marlboro 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 Roto-Molding Process Components
This moulding operation has been used since ancient times for creatingvseverl items. Egyptians for instance, applied rotomoulding procedures in the of ceramics. The Swiss were also employing this rotation design to generate hollow chocolate eggs. Some plastic product lines in the USA were manufactured using this method some time between 1940 and 1950. The process has however taken very long to catch on because it was looked at to be a pretty slow-moving process
1. Mold fitting.
A fixed amount of polymer in powder form is packed into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel material. The color tone needed for the final goods is pre compounded into the polymer. The most commonly used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this type of plastic assembly.
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 mould with the powdered polymer is then secured and inserted into the oven.
2. The heating up and fusion step.
Once within the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and coats the inside if the mold. The turning is done gradually, about 20 spins per min. The main thing that is critical at this moment is the period of time the mould will spend inside the oven. If it overstays, the material will lose value and durability, producing a weak item. If it is removed from the oven too early, the polymer will not have melted correctly, which creates bubbles in the finalized product.
3. Mould cooling down.
When the component has completely spent the right amount of time in the oven, it is then extracted 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 a little for ease of extraction from the mould. This is another step that depends a lot on the right timing, since quick cooling shrinks the material too rapidly, causing bending of the material.
4. The un-loading or de-molding phase.
When the component inside te mould has cooled properly, the person managing the process can then extract the completed item from the mold. 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 Marlboro NY 12542 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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