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Rotational molding refers to a plastic manufacturing practice that produces hollow stress-free products. The technique relies upon high temperatures and bi axial rotation to follow up with seamless, one piece items that have varying forms, sizes and colors. This method is also referred to as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The component that makes this unique from other plastic manufacturing processes because no pressure is needed. It also has few contenders when it involves the manufacture of sizable hollow products which are long lasting and inexpensive.There is a wide variety of product lines that are generated by this process including big water tanks, automobile materials, intricate designed medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is because of the flexibility in regards to style and shapes that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Bryn Athyn PA 19009, 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 Bryn Athyn 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 Components
This moulding procedure has been used since earlier times for creatingvseverl products. Egyptians for example, employed rotomoulding techniques in the making of ceramics. The Swiss were also making use of this rotation style to make hollow chocolate eggs. Some plastic product lines in the USA were made using this technique some time between 1940 and 1950. The system has however taken long to catch on because it was looked at as being a pretty slow process
1. Mould fitting.
A fixed quantity of polymer in powder form is packed into a hollow mould. The mold is usually made from cast aluminium or sheet steel component. The colour desired for the end item 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.
Pre-heating of the oven follows, and it can be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mould with the powdered polymer is then sealed and installed into the oven.
2. The heating and fusion phase.
Once inside the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done gradually, about 20 rotations per minute. One thing that is important at this moment is the amount of time the mould will spend inside the oven. If it stays to long, the material will lose stability and strength, producing a weak product. If it is taken out from the oven prematurely, the polymer will not have flowed correctly, which develops bubbles in the finished product.
3. Mold cooling down.
When the product 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 somewhat for ease of extraction from the mould. This is an additional step that depends a lot on the correct timing, since rapid cooling reduces the material too quick, causing warping of the material.
4. The removing or de-moulding step.
Once the product inside te mold has cooled effectively, the molder managing the procedure can then extract the finalized product from the mould. 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 Bryn Athyn PA 19009 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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