Looking for rotational molding alternatives in Pennsylvania? Want affordable custom plastic molding that is cost effective for Valley Forge area? Then give us a call at our toll free number 866-971-7861 or request a quote today!

rotational molding-Valley Forge-Rotational moulding pertains to a plastic production solution that generates 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 variety of forms, colors and sizes. This technique is also called roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl forms.

The attribute that makes this different from other plastic manufacturing techniques because no pressure is required. It also has few competitors when it pertains to the creation of large size hollow items which are resilient and inexpensive.There is a wide variety of product lines that are produced by this process including large size water tanks, automobile products, sophisticated molded medical items, recreation equipment, toys, kayaks, industrial equipment among many others.This is due to the versatility in regards to type 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 Valley Forge PA 19481, 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 roto-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

Plastic Molding-Valley Forge-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 Valley Forge 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 in Detail

This molding operation has been used since ancient times for creatingvseverl items. Egyptians as an example, applied rotational molding solutions in the producing of ceramics. The Swiss were also employing this rotation design to create hollow chocolate eggs. Some plastic product lines in the USA were created using this procedure some time between 1940 and 1950. The technique has however taken long to take affect because it was thought of to be a relatively slow process

1. Mold fitting.
A fixed amount of polymer in particle form is packed into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel material. The color tone preferred for the end goods is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this format of plastic engineering.

Pre-heating of the oven starts, and it can 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 locked and inserted into the oven.

2. The heating up and fusion step.
Once placed into the oven, the mold is spun on two axis so the powdered polymer melts from the heat and overlays the inside if the mold. The turning is done slowly, about 20 spins per min. One thing that is vital at this point is the period of time the mold will spend inside the oven. If it stays to long, the product will lose stability and durability, generating a poor item. If it is taken out from the oven too early, the polymer will not have melted correctly, which produces bubbles in the finished product line.

3. Mold cooling down.
When the product has sufficiently spent the right amount of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which generates a cool mist. When the product cools, it reduces somewhat for ease of removal from the mold. This is an additional step that depends upon a lot on the right timing, since quick cooling reduces the material too quick, causing warping of the product.

4. The offloading or de-moulding step.
As soon as the material within te mold has cooled correctly, the molder managing the process can then take out the finalized item from the mould. The process is repeated from the start, giving a number of exact products.

For more information on the different rotational molding options offered for the Valley Forge PA 19481 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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