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Rotational molding refers to a plastic manufacturing procedure that creates hollow stress-free products. The procedure relies upon high temperatures and bi axial rotation to come up with seamless, one piece items that have a wide range of forms, sizes and colors. This technique is also called rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The function that makes this different from other plastic manufacturing techniques that no pressure is involved. It also has few competitors when it comes down to the creation of large size hollow products which are resilient and inexpensive.There is a wide variety of product lines that are developed by this process including large water tanks, automobile products, sophisticated molded medical items, leisure equipment, toys, kayaks, industrialized equipment among many others.This is because of the versatility in regards to design and forms that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in York PA 17401, 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
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 York 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 Procedure in Detail
This moulding system has been used since earlier times for creatingvseverl items. Egyptians for instance, employed rotocasting solutions in the making of ceramics. The Swiss were also applying this rotation design to generate hollow chocolate eggs. Some plastic items in the USA were created using this approach some time between 1940 and 1950. Due to the fact that it was regarded to be a rather slow-moving technique, the process has however taken long to become popular
1. Mold prep work.
A fixed volume of polymer in powder form is filled into a hollow mould. The mold is usually constructed from cast aluminium or sheet steel material. The coloring wanted for the final product 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 style of plastic manufacturing.
Preheating of the oven follows, and it can be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mold with the powdered polymer is then sealed and installed within the oven.
2. The heat and fusion phase.
Once placed into the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The spinning is done slowly, about 20 spins per min. The main thing that is critical at this moment is the period of time the mold will spend within the oven. If it stays to long, the product will lose stability and durability, producing a weak product. If it is extracted from the oven prematurely, the polymer will not have liquefied properly, which creates bubbles in the finished product line.
3. Mould cooling.
When the material has sufficiently spent the enough 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 a cool mist. When the material cools, it reduces a little for ease of removal from the mold. This is an additional procedure that depends upon a lot on the correct timing, since quick cooling reduces the material too rapidly, causing warping of the item.
4. The unloading or de-molding phase.
When the material inside te mold has cooled successfully, the person managing the procedure can then remove the finished product from the mold. The technique is repeated from the start, providing a number of identical items.
For more information on the different rotational molding options offered for the York PA 17401 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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