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Rotational molding refers to a plastic production practice that makes hollow stress-free product lines. The process relies on high temperatures and bi axial rotation to come up with seamless, one piece objects that have several designs, colors and sizes. This technique is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The function that makes this unique from other plastic manufacturing procedures in that no pressure is called for. It also has few contenders when it comes to the production of large size hollow products which are durable and inexpensive.There is a wide variety of items that are created by this process including large water tanks, automobile products, intricate molded medical items, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to 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 Oak Harbor OH 43449, 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 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 Oak Harbor 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 Rotomolding Process in Detail
This moulding operation has been used since early times for creatingvseverl products. Egyptians for instance, applied rotomoulding techniques in the producing of ceramics. The Swiss were also working with this rotation design to create hollow chocolate eggs. Some plastic products in the USA were created using this approach some time between 1940 and 1950. The procedure has however taken very long to catch on because it was thought of as being a very slow-moving process
1. Mould fitting.
A predetermined volume of polymer in powder form is packed into a hollow mould. The mould is usually built from cast aluminium or sheet steel component. The coloring chosen for the finished goods is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this type of plastic engineering.
Pre-heating of the oven starts, and it may 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 locked and positioned inside the oven.
2. The heat and fusion procedure.
Once inside the oven, the mould is turned on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The spinning is done slowly, about 20 revolutions per minute. The main thing that is important at this point is the period of time the mold will spend within the oven. If it overstays, the product will lose value and durability, creating a weak product. If it is extracted from the oven prematurely, the polymer will not have melted properly, which develops bubbles in the finalized item.
3. Mold cooling down.
When the material has completely spent the right amount of time in the oven, it is then extracted 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 shrinks a little for ease of extraction from the mold. This is one more step that depends a lot on the correct timing, since rapid cooling shrinks the material too quick, causing warping of the product.
4. The un-loading or de-molding phase.
As soon as the component inside te mold has cooled correctly, the person handling the process can then take out the finished item from the mould. The process is repeated from the beginning, supplying a number of similar items.
For more information on the different rotational molding options offered for the Oak Harbor OH 43449, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
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