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Rotational molding refers to a plastic production procedure that generates hollow stress-free items. The technique relies on high temperatures and bi axial rotation to come up with seamless, one piece items that have a wide range of shapes, sizes and colors. This procedure is also referred to as rotomolding 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 required. It also has few rivals when it comes down to the manufacture of large hollow items which are resilient and inexpensive.There is a variety of product lines that are generated by this process including big water tanks, automobile products, intricate shaped medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is because of the flexibility in terms of style 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 Barto PA 19504, 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 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 Barto 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 Rotomolding Method Components
This molding technique has been used since earlier times for creatingvseverl products. Egyptians for example, applied rotomoulding methods in the making of ceramics. The Swiss were also using this rotation approach to make hollow chocolate eggs. Some plastic items in the USA were developed utilizing this technique some time between 1940 and 1950. The procedure has however taken long to catch on because it was looked at to be a rather slow process
1. Mold preparation.
A predetermined volume of polymer in grain form is packed into a hollow mold. The mold is usually built from cast aluminium or sheet steel material. The color needed for the finished product 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 format of plastic production.
Pre-heating of the oven starts, and it can 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 secured and positioned within the oven.
2. The heating up and fusion step.
Once inside the oven, the mould is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The rotation is done slowly and gradually, about 20 revolutions per sixty seconds. One thing that is crucial at this point is the period of time the mould will spend inside the oven. If it overstays, the component will lose stability and durability, making a faulty product. If it is taken out from the oven too early, the polymer will not have flowed correctly, which generates bubbles in the completed product line.
3. Mould cooling.
When the component has completely spent the enough of time in the oven, it is then taken out for cooling. This may be done by air or water, or sometimes a mixture of both which generates a cool mist. When the product cools, it reduces a little for ease of extraction from the mould. This is yet another step that relies a lot on the right timing, since quick cooling shrinks the material too quickly, causing warping of the product.
4. The removing or de-moulding phase.
As soon as the component inside te mould has cooled correctly, the person managing the procedure can then extract the finished item from the mould. The procedure is repeated from the beginning, providing a number of exact products.
For more information on the different rotational molding options offered for the Barto PA 19504 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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