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Rotational molding pertains to a plastic manufacturing technique that creates hollow stress-free product lines. The method depends on high temperatures and bi axial rotation to come up with seamless, one piece objects that have varying designs, sizes and colors. This method is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The attribute that makes this different from other plastic manufacturing processes in that no pressure is needed. It also has few rivals when it comes to the creation of large size hollow products which are long-lasting and inexpensive.There is a variety of items that are produced by this process including large size water tanks, automobile materials, intricate molded medical products, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to 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 Breinigsville PA 18031, 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 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 Breinigsville 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 Procedure in Detail
This molding technique has been used since early times for creatingvseverl products. Egyptians as an example, applied rotational molding techniques in the manufacturing of ceramics. The Swiss were also employing this rotation technique to create hollow chocolate eggs. Some plastic product lines in the USA were made using this approach some time between 1940 and 1950. The procedure has however taken very long to catch on because it was thought of as being a relatively slow-moving process
1. Mould fitting.
A fixed amount of polymer in particle form is filled into a hollow mold. The mold is usually made from cast aluminium or sheet steel substance. The coloration preferred for the finished goods 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 design of plastic assembly.
Preheating 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 mould with the powdered polymer is then sealed and installed inside the oven.
2. The heating and fusion procedure.
Once inside the oven, the mould is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The turning is done gradually, about 20 rotations per minute. One thing that is important at this point is the period of time the mold will spend within the oven. If it stays to long, the product will lose stability and durability, producing a weak item. If it is removed from the oven too early, the polymer will not have liquefied properly, which generates bubbles in the finished product.
3. Mould cooling.
When the component has sufficiently spent the correct 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 component cools, it reduces a little for ease of extraction from the mold. This is one more measure that depends a lot on the ideal timing, since rapid cooling decreases the material too fast, causing warping of the product.
4. The offloading or de-moulding phase.
When the component within te mould has cooled properly, the person taking care of the procedure can then extract the finished item from the mould. The procedure is repeated from the start, supplying a number of identical items.
For more information on the different rotational molding options offered for the Breinigsville PA 18031 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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