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Rotational moulding pertains to a plastic production practice 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 several forms, colors and sizes. This method is also referred to as roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The benefit that makes this different from other plastic manufacturing methods because no pressure is called for. It also has few competitors when it pertains to the manufacture of sizable hollow items which are durable and inexpensive.There is a wide range of product lines that are developed by this process including large size water tanks, automobile products, intricate shaped medical items, leisure equipment, toys, kayaks, industrial equipment among many others.This is due to the versatility in terms of type and forms that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Walters OK 73572, 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 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 Walters 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 Rotomoulding Process Components
This moulding technique has been used since earlier times for creatingvseverl products. Egyptians for instance, worked with roto-molding techniques in the of ceramics. The Swiss were also using this rotation type to create hollow chocolate eggs. Some plastic products in the USA were manufactured using this approach some time between 1940 and 1950. The procedure has however taken very long to take affect because it was considered as being a relatively slow process
1. Mould prep work.
A fixed quantity of polymer in powder form is loaded into a hollow mould. The mould is usually built from cast aluminium or sheet steel substance. The coloring preferred for the final 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 style of plastic engineering.
Preheating of the oven follows, 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 inside the oven.
2. The heating and fusion step.
Once placed into the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The spinning is done slowly and gradually, about 20 revolutions per sixty seconds. One thing that is crucial at this moment is the amount of time the mold will spend within the oven. If it overstays, the component will lose value and strength, producing a faulty item. If it is taken out from the oven too early, the polymer will not have liquefied properly, which creates bubbles in the finished product line.
3. Mold cooling.
When the product has sufficiently spent the correct amount of time in the oven, it is then taken out 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 shrinks a little for ease of extraction from the mould. This is yet another measure that relies a lot on the ideal timing, since rapid cooling reduces the material too quick, causing bending of the material.
4. The unloading or de-molding step.
Once the material within te mold has cooled properly, the molder managing the procedure can then remove the completed product from the mold. The procedure is repeated from the beginning, giving a number of identical products.
For more information on the different rotational rotomolding options offered for the Walters OK 73572 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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