Looking for rotational molding alternatives in Pennsylvania? Want affordable custom plastic molding that is cost effective for Imperial area? Then give us a call at our toll free number 866-971-7861 or request a quote today!
Rotational molding refers to a plastic manufacturing technique that makes hollow stress-free products. The technique utilizes high temperatures and bi axial rotation to follow up with seamless, one piece products that have various designs, sizes and colors. This technique is also known as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.
The benefit that makes this different from other plastic manufacturing techniques because no pressure is required. It also has few contenders when it involves the creation of large hollow products which are long lasting and inexpensive.There is a variety of items that are produced by this process including big water tanks, automobile products, intricate designed medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is because of the versatility in regards to type and shapes that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Imperial PA 15126, 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 rotomolding 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 Imperial 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 Process in Detail
This molding process has been used since earlier times for creatingvseverl products. Egyptians for instance, applied roto-molding methods in the of ceramics. The Swiss were also employing this rotation method to create hollow chocolate eggs. Some plastic products in the USA were created utilizing this method some time between 1940 and 1950. The process has however taken very long to catch on because it was looked at to be a pretty slow-moving process
1. Mold readying.
A fixed quantity of polymer in grain form is packed into a hollow mould. The mold is usually comprised of cast aluminium or sheet steel component. The color tone desired for the final item 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 manufacturing.
Preheating 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 mould with the powdered polymer is then sealed and placed inside the oven.
2. The heating up and fusion step.
Once inside the oven, the mould is turned on two axis so the powdered polymer melts from the heat and coats the inside if the mold. The spinning is done slowly, about 20 revolutions per sixty seconds. One thing that is vital at this point is the amount of time the mold will spend within the oven. If it overstays, the product will lose stability and strength, making a poor item. If it is taken out from the oven prematurely, the polymer will not have melted properly, which creates bubbles in the finalized product.
3. Mould cooling down.
When the product 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 creates a cool mist. When the component cools, it reduces slightly for ease of extraction from the mould. This is one more measure that depends a lot on the ideal timing, since quick cooling reduces the material too fast, causing warping of the product.
4. The un-loading or de-moulding phase.
When the component inside te mold has cooled properly, the molder handling the process can then remove the finished item from the mould. The function is repeated from the start, supplying a series of identical items.
For more information on the different rotational molding options offered for the Imperial PA 15126 area, please call our toll free number 866-971-7861 or fill out the form on the right for a consultation!
Other areas we service, go here to plastic molding