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Rotational molding refers to a plastic production practice that creates hollow stress-free items. The procedure relies on high temperatures and bi axial rotation to come up with seamless, one piece objects that have many different designs, sizes and colors. This procedure is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The component that makes this unique from other plastic manufacturing techniques because no pressure is called for. It also has few rivals when it pertains to the creation of sizable hollow items which are durable and inexpensive.There is a wide range of product lines that are generated by this process including large water tanks, automobile materials, sophisticated shaped medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is because of the versatility in terms of type and forms that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Blue Bell PA 19422, 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 Blue Bell 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 in Detail
This molding method has been used since early times for creatingvseverl items. Egyptians as an example, applied rotocasting solutions in the of ceramics. The Swiss were also working with this rotation technique to generate hollow chocolate eggs. Some plastic products in the USA were made utilizing this technique some time between 1940 and 1950. The technique has however taken long to take affect because it was thought of to be a somewhat slow-moving process
1. Mould readying.
A predetermined volume of polymer in particle form is filled into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel substance. The coloration desired for the finished item 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 type of plastic engineering.
Pre-heating of the oven follows, and it can 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 locked and inserted inside the oven.
2. The heating up and fusion procedure.
Once inside the oven, the mold is turned 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 sixty seconds. The main thing that is critical at this moment is the amount of time the mold will spend inside the oven. If it stays to long, the material will lose stability and strength, making a faulty item. If it is removed from the oven prematurely, the polymer will not have melted properly, which produces bubbles in the completed product.
3. Mould cooling.
When the material has completely spent the right amount of time in the oven, it is then extracted for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the material cools, it shrinks slightly for ease of removal from the mould. This is one more procedure that depends a lot on the ideal timing, since rapid cooling reduces the material too rapidly, causing warping of the item.
4. The removing or de-moulding step.
As soon as the product inside te mould has cooled effectively, the molder handling the process can then take out the completed item from the mould. The technique is repeated from the start, giving a series of identical product lines.
For more information on the different rotational molding options offered for the Blue Bell PA 19422 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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