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Rotational moulding refers to a plastic production procedure that generates hollow stress-free product lines. The method relies on high temperatures and bi axial rotation to come up with seamless, one piece objects that have many different shapes, colors and sizes. This method is also called rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The component that makes this different from other plastic manufacturing processes that no pressure is needed. It also has few rivals when it comes down to the production of large hollow items which are durable and inexpensive.There is a wide range of product lines that are developed by this process including large size water tanks, automobile items, sophisticated shaped medical items, leisure equipment, toys, kayaks, industrial equipment among many others.This is due to the versatility in terms of design and forms that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Honesdale PA 18431, 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 moulding 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 Honesdale 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 Method Components
This molding operation has been used since earlier times for creatingvseverl product lines. Egyptians for example, employed rotational molding techniques in the making of ceramics. The Swiss were also making use of this rotation method to create hollow chocolate eggs. Some plastic product lines in the USA were made using this technique some time between 1940 and 1950. Because it was viewed to be a relatively slow process, the method has however taken long to catch on
1. Mould readying.
A predetermined measure of polymer in powder form is loaded into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel material. The coloration intended for the end product 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 to temperatures between 500-700F. The mold with the powdered polymer is then sealed and put inside the oven.
2. The heating and fusion phase.
Once inside the oven, the mould is turned on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The turning is done slowly, about 20 revolutions per min. The main thing that is critical at this point is the amount of time the mold will spend inside the oven. If it overstays, the material will lose stability and strength, creating a weak item. If it is taken out from the oven prematurely, the polymer will not have liquefied properly, which creates bubbles in the completed item.
3. Mold cooling.
When the material has completely spent the correct amount of time in the oven, it is then removed 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 somewhat for ease of extraction from the mould. This is another measure that relies a lot on the right timing, since quick cooling reduces the material too quickly, causing bending of the product.
4. The discharging or de-molding phase.
As soon as the material within te mold has cooled adequately, the person taking care of the process can then extract the completed product from the mould. The process is repeated from the beginning, supplying a number of similar product lines.
For more information on the different rotational molding options offered for the Honesdale PA 18431 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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