Looking for rotational molding alternatives in Pennsylvania? Want affordable custom plastic molding that is cost effective for Berwyn 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 manufacturing solution that creates hollow stress-free items. The process relies upon high temperatures and bi axial rotation to come up with seamless, one piece products that have many different shapes, colors and sizes. This method is also known as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The component that makes this different from other plastic manufacturing methods because no pressure is needed. It also has few rivals when it comes down to the creation of large size hollow products which are long-lasting and inexpensive.There is a wide variety of products that are produced by this process including big water tanks, automobile materials, sophisticated shaped medical items, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of design and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Berwyn PA 19312, 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 rotomolding 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 Berwyn 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 Rotomoulding Process Components
This moulding technique has been used since early times for creatingvseverl product lines. Egyptians for instance, worked with rotational molding solutions in the making of ceramics. The Swiss were also utilizing this rotation method to make hollow chocolate eggs. Some plastic items in the USA were manufactured using this procedure some time between 1940 and 1950. Because it was looked at to be a relatively slow-moving technique, the process has however taken long to become popular
1. Mold fitting.
A predetermined measure of polymer in powder form is filled into a hollow mould. The mould is usually composeded of cast aluminium or sheet steel component. The color needed 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 format of plastic manufacturing.
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 mould with the powdered polymer is then locked and installed inside the oven.
2. The heating up and fusion process.
Once inside the oven, the mould is spun on two axis so the powdered polymer melts from the heat and coats the inside if the mold. The rotation is done gradually, about 20 spins per minute. Something that is essential at this point is the period of time the mold will spend within the oven. If it stays to long, the material will lose value and strength, producing a weak product. If it is removed from the oven too early, the polymer will not have flowed correctly, which creates bubbles in the completed item.
3. Mould cooling.
When the material has sufficiently spent the right amount 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 one more measure that relies a lot on the ideal timing, since quick cooling shrinks the material too fast, causing bending of the product.
4. The offloading or de-molding phase.
As soon as the product inside te mould has cooled properly, the molder handling the process can then extract the finished item from the mold. The function is repeated from the beginning, giving a number of exact items.
For more information on the different rotational molding options offered for the Berwyn PA 19312 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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