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Rotational moulding pertains to a plastic manufacturing technique that produces hollow stress-free products. The function relies on high temperatures and bi axial rotation to follow up with seamless, one piece products that have a wide range of designs, sizes and colors. This technique is also referred to as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The benefit that makes this different from other plastic manufacturing techniques that no pressure is involved. It also has few rivals when it comes to the creation of sizable hollow items which are durable and inexpensive.There is a wide variety of product lines that are developed by this process including large water tanks, automobile products, intricate shaped medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is due to the versatility in regards to design 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 Cocolamus PA 17014, 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 rotocasting 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 Cocolamus 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 in Detail
This molding system has been used since early times for creatingvseverl product lines. Egyptians as an example, worked with rotocasting techniques in the of ceramics. The Swiss were also working with this rotation style to generate hollow chocolate eggs. Some plastic products in the USA were created using this procedure some time between 1940 and 1950. The process has however taken long to catch on because it was thought of to be a relatively slow-moving process
1. Mold prep work.
A predetermined quantity of polymer in particle form is packed into a hollow mold. The mould is usually comprised of cast aluminium or sheet steel material. The color needed for the finished product 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 manufacturing.
Preheating of the oven starts, and it may be done by either conduction, convection or sometimes radiation. It is heated 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 placed into the oven, the mold is turned on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done slowly and gradually, about 20 revolutions per min. The main thing that is essential at this point is the amount of time the mold will spend inside the oven. If it overstays, the material will lose stability and durability, creating a faulty product. If it is taken out from the oven prematurely, the polymer will not have flowed properly, which generates bubbles in the completed product.
3. Mould cooling down.
When the product has sufficiently 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 a cool mist. When the material cools, it shrinks a little for ease of extraction from the mould. This is yet another procedure that depends a lot on the correct timing, since rapid cooling reduces the material too quick, causing warping of the product.
4. The unloading or de-moulding step.
As soon as the component inside te mould has cooled adequately, the person managing the process can then remove the finished item from the mould. The function is repeated from the beginning, supplying a series of exact items.
For more information on the different rotational molding options offered for the Cocolamus PA 17014 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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