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Rotational moulding pertains to a plastic production practice that generates hollow stress-free items. The procedure uses high temperatures and bi axial rotation to come up with seamless, one piece items that have different designs, colors and sizes. This technique is also called rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The feature that makes this unique from other plastic manufacturing methods because no pressure is needed. It also has few competitors when it comes down to the creation of large hollow items which are long-lasting and inexpensive.There is a wide variety of products that are generated by this process including large water tanks, automobile materials, complex designed medical products, leisure equipment, toys, canoes, industrial equipment among many others.This is due to the flexibility in terms of style 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 Park Hill OK 74451, 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 Oklahoma 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 Park Hill Oklahoma 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 in Detail
This moulding method has been used since earlier times for creatingvseverl items. Egyptians as an example, worked with roto-molding techniques in the manufacturing of ceramics. The Swiss were also making use of this rotation format to create hollow chocolate eggs. Some plastic items in the USA were created using this approach some time between 1940 and 1950. The system has however taken long to take affect because it was thought of as being a rather slow-moving process
1. Mould readying.
A predetermined amount of polymer in grain form is loaded into a hollow mould. The mold is usually constructed from cast aluminium or sheet steel material. The colour intended for the finished product 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 format of plastic assembly.
Preheating 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 mould with the powdered polymer is then locked and installed within the oven.
2. The heat and fusion step.
Once within the oven, the mould is revolved on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The rotation is done slowly, about 20 revolutions per sixty seconds. The main thing that is essential at this point is the period of time the mold will spend within the oven. If it overstays, the material will lose stability and durability, generating a faulty product. If it is extracted from the oven too early, the polymer will not have melted correctly, which develops bubbles in the completed item.
3. Mould cooling.
When the material has completely spent the correct 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 a cool mist. When the product cools, it shrinks slightly for ease of removal from the mold. This is another procedure that depends upon a lot on the correct timing, since quick cooling decreases the material too rapidly, causing bending of the material.
4. The unloading or de-moulding step.
Once the material within te mold has cooled effectively, the person managing the operation can then remove the finalized product from the mold. The process is repeated from the start, making a series of similar product lines.
For more information on the different rotational rotomolding options offered for the Park Hill OK 74451 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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