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Rotational molding refers to a plastic manufacturing technique that generates hollow stress-free products. The function relies upon high temperatures and bi axial rotation to come up with seamless, one piece products that have several forms, colors and sizes. This procedure is also known as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.
The component that makes this different from other plastic manufacturing methods because no pressure is called for. It also has few rivals when it involves the production of large hollow products which are resilient and inexpensive.There is a variety of items that are created by this process including big water tanks, automobile items, complex designed medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is due to the versatility in terms of style 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 Gradyville PA 19039, 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 Gradyville 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 Rotomolding Procedure Components
This moulding process has been used since early times for creatingvseverl items. Egyptians for example, applied rotational molding procedures in the manufacturing of ceramics. The Swiss were also applying this rotation design to generate hollow chocolate eggs. Some plastic items in the USA were developed utilizing this approach some time between 1940 and 1950. The technique has however taken long to take affect because it was considered to be a very slow process
1. Mold preparation.
A predetermined amount of polymer in particle form is packed into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel component. The color chosen for the final product 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 type of plastic production.
Pre-heating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then secured and placed inside the oven.
2. The heating and fusion step.
Once inside the oven, the mold is spun on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The turning is done slowly and gradually, about 20 revolutions per min. One thing that is crucial at this point is the period of time the mould will spend within the oven. If it stays to long, the material will lose value and durability, producing a poor product. If it is taken out from the oven too early, the polymer will not have melted correctly, which creates bubbles in the finalized product.
3. Mold cooling.
When the product 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 generates a cool mist. When the product cools, it shrinks a little for ease of removal from the mold. This is an additional measure that depends upon a lot on the ideal timing, since rapid cooling reduces the material too fast, causing warping of the material.
4. The un-loading or de-molding phase.
When the material within te mold has cooled adequately, the person taking care of the operation can then remove the finished product from the mould. The technique is repeated from the beginning, making a number of exact products.
For more information on the different rotational molding options offered for the Gradyville PA 19039 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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