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rotational moulding-Dalton-Rotational molding refers to a plastic manufacturing technique that creates hollow stress-free items. The process relies upon high temperatures and bi axial rotation to follow up with seamless, one piece items that have varying designs, colors and sizes. This technique is also known as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.

The feature that makes this unique from other plastic manufacturing processes because no pressure is involved. It also has few competitors when it pertains to the creation of large size hollow products which are long lasting and inexpensive.There is a wide range of product lines that are produced by this process including big water tanks, automobile materials, complex molded medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is because of the flexibility in terms of design and shapes that the process makes

Benefits of Using Rotomolding to Manufacture Plastic Products

  • Relatively low tooling costs.
    When compared to other plastic manufacturing processes in Dalton OH 44618, 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

Custom Molded-Dalton-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 Ohio 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 Dalton Ohio 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 molding system has been used since earlier times for creatingvseverl items. Egyptians as an example, applied roto-molding procedures in the creating of ceramics. The Swiss were also employing this rotation type to make hollow chocolate eggs. Some plastic product lines in the USA were manufactured utilizing this method some time between 1940 and 1950. The process has however taken very long to catch on because it was thought of to be a pretty slow process

1. Mould prep work.
A fixed amount of polymer in grain form is packed into a hollow mold. The mold is usually constructed from cast aluminium or sheet steel component. The coloring preferred for the final product 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 style of plastic production.

Pre-heating of the oven follows, and it can be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mold with the powdered polymer is then locked and inserted inside the oven.

2. The heating and fusion phase.
Once placed into the oven, the mould is turned on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The turning is done slowly, about 20 spins per minute. Something that is critical at this moment is the amount of time the mold will spend inside the oven. If it overstays, the product will lose value and durability, making a faulty item. If it is taken out from the oven prematurely, the polymer will not have melted properly, which generates bubbles in the finalized item.

3. Mould cooling down.
When the product has completely spent the correct amount of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the component cools, it reduces a little for ease of removal from the mold. This is an additional measure that depends a lot on the correct timing, since rapid cooling shrinks the material too quickly, causing bending of the product.

4. The offloading or de-molding phase.
As soon as the material within te mould has cooled correctly, the molder handling the process can then remove the completed product from the mould. The technique is repeated from the start, providing a series of similar items.

For more information on the different rotational molding options offered for the Dalton OH 44618, please call our toll free number  866-971-7861 or fill out the form on the right for a consultation!

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