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Rotational molding refers to a plastic production technique that creates 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 shapes, colors and sizes. This technique is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The attribute that makes this unique from other plastic manufacturing procedures because no pressure is required. It also has few rivals when it pertains to the manufacture of large hollow products which are resilient and inexpensive.There is a wide range of product lines that are generated by this process including big water tanks, automobile products, sophisticated designed medical products, recreation equipment, toys, canoes, industrialized equipment among many others.This is because of the versatility in regards to design and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Eastlake OH 44095, 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 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 Eastlake 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 moulding method has been used since early times for creatingvseverl items. Egyptians as an example, worked with roto-molding procedures in the making of ceramics. The Swiss were also working with this rotation format to generate hollow chocolate eggs. Some plastic product lines in the USA were developed using this procedure some time between 1940 and 1950. The process has however taken long to take affect because it was thought of to be a relatively slow-moving process
1. Mould prep work.
A fixed amount of polymer in particle form is packed into a hollow mold. The mould is usually made from cast aluminium or sheet steel substance. The color tone desired for the end item 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 production.
Preheating 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 mould with the powdered polymer is then secured and inserted within the oven.
2. The heating up and fusion phase.
Once within the oven, the mould is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The rotation is done gradually, about 20 spins per minute. Something that is critical at this point is the amount of time the mold will spend within the oven. If it overstays, the product will lose stability and strength, making a weak item. If it is removed from the oven prematurely, the polymer will not have flowed correctly, which generates bubbles in the completed product.
3. Mould cooling.
When the component has completely spent the right 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 creates a cool mist. When the product cools, it reduces a little for ease of removal from the mould. This is an additional step that depends upon a lot on the ideal timing, since rapid cooling reduces the material too rapidly, causing warping of the material.
4. The offloading or de-molding phase.
As soon as the product inside te mold has cooled effectively, the molder handling the process can then take out the completed product from the mould. The function is repeated from the start, providing a number of exact items.
For more information on the different rotational molding options offered for the Eastlake OH 44095, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
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