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Rotational molding refers to a plastic production method that creates hollow stress-free products. The procedure relies on high temperatures and bi axial rotation to come up with seamless, one piece items that have varying shapes, sizes and colors. This procedure is also called roto-molding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The feature that makes this different from other plastic manufacturing processes because no pressure is involved. It also has few rivals when it comes down to the creation of sizable hollow products which are long-lasting and inexpensive.There is a variety of items that are developed by this process including big water tanks, automobile items, intricate shaped medical products, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the versatility in terms of style 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 Broad Top PA 16621, 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 Broad Top 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 items. Egyptians for example, worked with rotocasting procedures in the producing of ceramics. The Swiss were also working with this rotation style to create hollow chocolate eggs. Some plastic product lines in the USA were manufactured using this approach some time between 1940 and 1950. Since it was thought of to be a fairly slow-moving procedure, the approach has however taken long to become popular
1. Mould prep work.
A fixed measure of polymer in powder form is filled into a hollow mould. The mould is usually built from cast aluminium or sheet steel component. The colour preferred for the end goods is pre compounded into the polymer. The most generally used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this format of plastic manufacturing.
Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then sealed and positioned within the oven.
2. The heating and fusion phase.
Once inside the oven, the mould is spun on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The rotation is done gradually, about 20 revolutions per minute. One thing that is crucial at this moment is the amount of time the mould will spend within the oven. If it overstays, the component will lose stability and strength, making a poor product. If it is taken out from the oven too early, the polymer will not have melted correctly, which generates bubbles in the finished product line.
3. Mold cooling down.
When the product has sufficiently spent the right amount of time in the oven, it is then extracted 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 shrinks a little for ease of extraction from the mold. This is yet another measure that depends upon a lot on the ideal timing, since rapid cooling reduces the material too quick, causing bending of the material.
4. The discharging or de-moulding phase.
When the product within te mold has cooled correctly, the molder handling the procedure can then take out the finalized product from the mold. The function is repeated from the beginning, supplying a series of identical products.
For more information on the different rotational molding options offered for the Broad Top PA 16621 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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