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Rotational moulding refers to a plastic manufacturing practice that generates hollow stress-free items. The method depends on high temperatures and bi axial rotation to come up with seamless, one piece objects that have several designs, colors and sizes. This method is also known as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The component that makes this different from other plastic manufacturing procedures that no pressure is involved. It also has few contenders when it involves the production of sizable hollow items which are resilient and inexpensive.There is a wide range of items that are created by this process including big water tanks, automobile products, intricate molded medical products, leisure equipment, toys, kayaks, industrialized equipment among many others.This is because of the flexibility in regards to design 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 Abington PA 19001, 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 Pennsylvania 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 Abington Pennsylvania 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 method has been used since ancient times for creatingvseverl items. Egyptians for instance, employed rotocasting solutions in the manufacturing of ceramics. The Swiss were also using this rotation type to generate hollow chocolate eggs. Some plastic products in the USA were created using this method some time between 1940 and 1950. Due to the fact that it was considered to be a rather slow approach, the process has however taken long to catch on
1. Mould preparation.
A predetermined measure of polymer in powder form is packed into a hollow mould. The mould is usually crafted from cast aluminium or sheet steel material. The coloring desired for the finished goods 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 type of plastic production.
Pre-heating of the oven follows, and it may 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 positioned inside the oven.
2. The heating and fusion procedure.
Once inside the oven, the mould is rotated on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The turning is done slowly and gradually, about 20 rotations per sixty seconds. Something that is critical at this moment is the amount of time the mold will spend within the oven. If it overstays, the product will lose stability and strength, making a poor product. If it is taken out from the oven prematurely, the polymer will not have liquefied properly, which produces bubbles in the finalized product line.
3. Mold cooling.
When the component has sufficiently spent the correct 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 generates a cool mist. When the component cools, it reduces a little for ease of removal from the mould. This is one more step that relies a lot on the correct timing, since rapid cooling shrinks the material too fast, causing warping of the material.
4. The removing or de-moulding phase.
Once the product inside te mold has cooled successfully, the molder taking care of the process can then take out the completed product from the mould. The process is repeated from the beginning, providing a series of identical items.
For more information on the different rotational molding options offered for the Abington PA 19001 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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