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Rotational moulding pertains to a plastic production procedure that generates hollow stress-free items. The method relies on high temperatures and bi axial rotation to come up with seamless, one piece products that have a wide range of shapes, sizes and colors. This method is also known as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The attribute that makes this unique from other plastic manufacturing procedures that no pressure is needed. It also has few contenders when it comes down to the production of large hollow products which are long-lasting and inexpensive.There is a wide variety of product lines that are created by this process including big water tanks, automobile materials, intricate shaped medical products, recreation equipment, toys, kayaks, industrial equipment among many others.This is because of the flexibility in terms of type and shapes that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Camp Hill PA 17001, 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 rotomoulding 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 Camp Hill 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 Components
This moulding process has been used since early times for creatingvseverl items. Egyptians as an example, utilized roto-molding systems in the manufacturing of ceramics. The Swiss were also using this rotation style to make hollow chocolate eggs. Some plastic products in the USA were manufactured using this technique some time between 1940 and 1950. The process has however taken very long to catch on because it was considered to be a rather slow process
1. Mold prep work.
A predetermined quantity of polymer in particle form is packed into a hollow mould. The mould is usually made from cast aluminium or sheet steel component. The coloring chosen for the end product 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 style of plastic engineering.
Pre-heating of the oven starts, 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 placed inside the oven.
2. The heat and fusion step.
Once inside the oven, the mold is turned on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The spinning is done gradually, about 20 revolutions per minute. One thing that is crucial at this point is the period of time the mold will spend inside the oven. If it overstays, the material will lose value and strength, generating a weak product. If it is extracted from the oven too early, the polymer will not have liquefied correctly, which develops bubbles in the finalized item.
3. Mold cooling down.
When the component has completely spent the enough 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 creates a cool mist. When the product cools, it reduces slightly for ease of removal from the mold. This is an additional step that depends a lot on the ideal timing, since rapid cooling reduces the material too rapidly, causing bending of the item.
4. The offloading or de-molding phase.
As soon as the component inside te mould has cooled adequately, the person managing the procedure can then take out the completed product from the mould. The technique is repeated from the start, supplying a series of exact product lines.
For more information on the different rotational molding options offered for the Camp Hill PA 17001 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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