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Rotational moulding refers to a plastic manufacturing method that produces hollow stress-free products. The function uses high temperatures and bi axial rotation to follow up with seamless, one piece objects that have a wide range of designs, sizes and colors. This method is also known as rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The function that makes this unique from other plastic manufacturing methods that no pressure is required. It also has few contenders when it pertains to the manufacture of large hollow items which are long lasting and inexpensive.There is a wide range of items that are generated by this process including large water tanks, automobile materials, complex shaped medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is because of the versatility in terms of style and shapes that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Clinton PA 15026, 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 Clinton 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 Method Components
This molding operation has been used since ancient times for creatingvseverl items. Egyptians for example, employed roto-molding solutions in the manufacturing of ceramics. The Swiss were also employing this rotation type to create hollow chocolate eggs. Some plastic products in the USA were developed utilizing this method some time between 1940 and 1950. The procedure has however taken long to take affect because it was looked at to be a pretty slow-moving process
1. Mold prep work.
A predetermined quantity of polymer in powder form is packed into a hollow mold. The mold is usually comprised of cast aluminium or sheet steel component. The color tone preferred for the finished goods is pre compounded into the polymer. The most typically used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this design of plastic engineering.
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 mold with the powdered polymer is then locked and positioned into the oven.
2. The heating up and fusion procedure.
Once placed into the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and overlays the inside if the mould. The rotation is done gradually, about 20 rotations per sixty seconds. The main thing that is essential at this point is the amount of time the mould will spend within the oven. If it stays to long, the component will lose value and strength, producing a poor product. If it is extracted from the oven too early, the polymer will not have flowed properly, which generates bubbles in the finalized product.
3. Mould cooling down.
When the component has completely spent the correct amount of time in the oven, it is then extracted for cooling. This can be done by air or water, or sometimes a mixture of both which generates a cool mist. When the component cools, it shrinks slightly for ease of extraction from the mold. This is an additional procedure that depends a lot on the ideal timing, since rapid cooling reduces the material too quick, causing warping of the material.
4. The un-loading or de-moulding step.
When the component within te mould has cooled correctly, the person managing the procedure can then remove the finalized product from the mould. The procedure is repeated from the beginning, making a number of similar product lines.
For more information on the different rotational molding options offered for the Clinton PA 15026 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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