Looking for rotational molding alternatives in Pennsylvania? Want affordable custom plastic molding that is cost effective for Aston area? Then give us a call at our toll free number 866-971-7861 or request a quote today!
Rotational molding pertains to a plastic production practice that generates hollow stress-free product lines. The procedure relies on high temperatures and bi axial rotation to follow up with seamless, one piece items that have different shapes, colors and sizes. This technique is also called rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The component that makes this unique from other plastic manufacturing methods that no pressure is called for. It also has few contenders when it comes to the creation of large hollow products which are durable and inexpensive.There is a wide variety of items that are produced by this process including big water tanks, automobile products, sophisticated shaped medical items, leisure equipment, toys, canoes, commercial equipment among many others.This is due to the versatility in terms of type and forms that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Aston PA 19014, 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 roto-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 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 Aston 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 Procedure in Detail
This moulding system has been used since ancient times for creatingvseverl product lines. Egyptians for example, utilized roto-molding techniques in the manufacturing of ceramics. The Swiss were also utilizing this rotation technique to make hollow chocolate eggs. Some plastic items in the USA were manufactured utilizing this technique some time between 1940 and 1950. The process has however taken long to catch on because it was considered as being a moderately slow-moving process
1. Mold readying.
A fixed quantity of polymer in particle form is loaded into a hollow mold. The mold is usually made of cast aluminium or sheet steel material. The colour chosen for the end 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 type of plastic engineering.
Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then secured and positioned inside the oven.
2. The heating up and fusion step.
Once within the oven, the mould is rotated on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done slowly, about 20 rotations per min. The main thing that is crucial at this point is the period of time the mold will spend inside the oven. If it stays to long, the material will lose stability and strength, making a weak product. If it is removed from the oven too early, the polymer will not have flowed correctly, which produces bubbles in the finalized item.
3. Mold cooling.
When the material 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 generates a cool mist. When the product cools, it reduces somewhat for ease of extraction from the mold. This is another measure that depends upon a lot on the ideal timing, since quick cooling reduces the material too rapidly, causing warping of the product.
4. The un-loading or de-molding step.
As soon as the product within te mold has cooled adequately, the molder managing the operation can then remove the finished product from the mold. The procedure is repeated from the start, giving a series of identical product lines.
For more information on the different rotational molding options offered for the Aston PA 19014 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
Other areas we service, go here to custom molded