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Rotational moulding refers to a plastic manufacturing procedure that produces hollow stress-free products. The function depends on high temperatures and bi axial rotation to follow up with seamless, one piece items that have varying forms, sizes and colors. This procedure is also called rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The component that makes this different from other plastic manufacturing methods because no pressure is called for. It also has few rivals when it comes to the creation of large size hollow items which are durable and inexpensive.There is a variety of product lines that are produced by this process including large water tanks, automobile products, intricate shaped medical items, recreation equipment, toys, canoes, commercial equipment among many others.This is because of the flexibility in regards to style and shapes that the process creates
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Clarks Summit PA 18411, 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 Clarks Summit 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 Rotomoulding Procedure Components
This moulding procedure has been used since early times for creatingvseverl product lines. Egyptians for instance, utilized rotomoulding solutions in the of ceramics. The Swiss were also making use of this rotation method to create hollow chocolate eggs. Some plastic items in the USA were developed using this approach some time between 1940 and 1950. The procedure has however taken long to take affect because it was thought of to be a very slow process
1. Mould prep work.
A predetermined measure of polymer in grain form is packed into a hollow mould. The mould is usually crafted from cast aluminium or sheet steel substance. The colour intended for the final goods is pre compounded into the polymer. The most commonly used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this format of plastic production.
Preheating 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 mold with the powdered polymer is then sealed and inserted within the oven.
2. The heat and fusion step.
Once inside the oven, the mold is turned on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The rotation is done slowly, about 20 revolutions per sixty seconds. One thing that is important at this moment is the amount of time the mould will spend within the oven. If it overstays, the material will lose value and durability, making a weak product. If it is removed from the oven prematurely, the polymer will not have melted correctly, which generates bubbles in the finalized product.
3. Mould cooling.
When the material 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 creates a cool mist. When the product cools, it shrinks a little for ease of removal from the mould. This is one more procedure that depends upon a lot on the right timing, since quick cooling shrinks the material too fast, causing bending of the item.
4. The discharging or de-moulding phase.
Once the product within te mold has cooled correctly, the person handling the procedure can then remove the finalized item from the mould. The technique is repeated from the start, making a number of exact items.
For more information on the different rotational molding options offered for the Clarks Summit PA 18411 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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