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Rotational molding refers to a plastic production solution that makes hollow stress-free items. The function utilizes high temperatures and bi axial rotation to come up with seamless, one piece products that have a wide range of forms, sizes and colors. This procedure is also referred to as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl styles.
The feature that makes this different from other plastic manufacturing techniques in that no pressure is needed. It also has few contenders when it involves the production of large size hollow products which are resilient and inexpensive.There is a wide variety of product lines that are created by this process including big water tanks, automobile products, intricate designed medical products, leisure equipment, toys, canoes, commercial equipment among many others.This is due to the flexibility in regards to style 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 Winnsboro SC 29180, 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 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 South Carolina 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 Winnsboro South Carolina 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 Method Components
This moulding system has been used since early times for creatingvseverl products. Egyptians for instance, worked with roto-molding systems in the of ceramics. The Swiss were also working with this rotation style to make hollow chocolate eggs. Some plastic product lines in the USA were manufactured using this procedure some time between 1940 and 1950. Since it was regarded to be a fairly slow method, the process has however taken long to catch on
1. Mould preparation.
A predetermined amount of polymer in powder form is packed into a hollow mold. The mould is usually made from cast aluminium or sheet steel component. The colour needed for the finished goods 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 assembly.
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 sealed and placed inside the oven.
2. The heating and fusion process.
Once within the oven, the mould is revolved on two axis so the powdered polymer melts from the heat and layers the inside if the mold. The spinning is done slowly, about 20 revolutions per min. The main thing that is important at this moment is the period of time the mould will spend inside the oven. If it stays to long, the material will lose value and durability, making a weak product. If it is taken out from the oven prematurely, the polymer will not have flowed correctly, which develops bubbles in the finalized item.
3. Mold cooling.
When the product has completely spent the right amount of time in the oven, it is then taken out for cooling. This may be done by air or water, or sometimes a mixture of both which creates a cool mist. When the component cools, it shrinks somewhat for ease of removal from the mold. This is another step that depends upon a lot on the correct timing, since quick cooling shrinks the material too quickly, causing bending of the material.
4. The un-loading or de-molding step.
As soon as the material within te mould has cooled properly, the person handling the procedure can then remove the completed item from the mould. The function is repeated from the beginning, giving a series of similar products.
For more information on the different rotational rotomolding options offered for the Winnsboro SC 29180 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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