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Rotational molding refers to a plastic manufacturing method that generates hollow stress-free products. The process utilizes high temperatures and bi axial rotation to come up with seamless, one piece products that have many different shapes, colors and sizes. This method is also known as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The attribute that makes this unique from other plastic manufacturing processes in that no pressure is called for. It also has few contenders when it comes to the production of large size hollow products which are resilient and inexpensive.There is a variety of items that are generated by this process including big water tanks, automobile materials, sophisticated molded medical products, recreation equipment, toys, canoes, industrial equipment among many others.This is due to the flexibility in regards to design and shapes that the process develops
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Lynnville TN 38472, 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 rotomoulding 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 Tennessee 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 Lynnville Tennessee 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 moulding process has been used since early times for creatingvseverl product lines. Egyptians as an example, employed rotocasting solutions in the making of ceramics. The Swiss were also using this rotation method to make hollow chocolate eggs. Some plastic items in the USA were made utilizing this procedure some time between 1940 and 1950. The technique has however taken long to catch on because it was looked at as being a rather slow process
1. Mould preparation.
A fixed measure of polymer in particle form is loaded into a hollow mould. The mold is usually made from cast aluminium or sheet steel component. The coloring desired 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 style of plastic engineering.
Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated up to temperatures between 500-700F. The mold with the powdered polymer is then secured and placed within the oven.
2. The heating up and fusion procedure.
Once within the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and layers the inside if the mold. The turning is done slowly and gradually, about 20 revolutions per sixty seconds. One thing that is critical at this point is the amount of time the mould will spend within the oven. If it overstays, the material will lose stability and durability, creating a weak product. If it is taken out from the oven too early, the polymer will not have melted properly, which generates bubbles in the completed product.
3. Mold cooling.
When the product has sufficiently spent the correct 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 a cool mist. When the material cools, it shrinks somewhat for ease of extraction from the mold. This is an additional measure that depends a lot on the correct timing, since quick cooling decreases the material too quickly, causing bending of the item.
4. The removing or de-molding step.
As soon as the product within te mold has cooled effectively, the molder managing the process can then take out the finished product from the mould. The procedure is repeated from the start, giving a number of exact items.
For more information on the different rotational molding options offered for the Lynnville TN 38472 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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