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Rotational moulding pertains to a plastic manufacturing technique that generates hollow stress-free items. The procedure depends on high temperatures and bi axial rotation to follow up with seamless, one piece items that have many different forms, colors and sizes. This method is also called rotomolding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl forms.
The feature that makes this different from other plastic manufacturing processes that no pressure is required. It also has few contenders when it comes to the production of large hollow items which are long-lasting and inexpensive.There is a wide range of product lines that are created by this process including large water tanks, automobile products, intricate molded medical products, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in regards to type and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Rockford TN 37853, 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 rotocasting 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 Rockford 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 Components
This moulding method has been used since early times for creatingvseverl items. Egyptians for instance, used rotational molding solutions in the making of ceramics. The Swiss were also utilizing this rotation approach to create hollow chocolate eggs. Some plastic product lines in the USA were created utilizing this procedure some time between 1940 and 1950. The process has however taken very long to catch on because it was thought of to be a very slow-moving process
1. Mould preparation.
A fixed quantity of polymer in particle form is loaded into a hollow mould. The mould is usually made from cast aluminium or sheet steel material. The colour preferred for the finished product is pre compounded into the polymer. The most typically 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 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 locked and placed into the oven.
2. The heat and fusion process.
Once placed into the oven, the mold is revolved on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The rotation is done slowly, about 20 revolutions per min. The main thing that is vital at this point is the period of time the mould will spend inside the oven. If it stays to long, the material will lose stability and strength, producing a faulty item. If it is taken out from the oven too early, the polymer will not have flowed correctly, which develops bubbles in the finalized product line.
3. Mold cooling.
When the material has sufficiently spent the enough 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 generates a cool mist. When the material cools, it shrinks slightly for ease of extraction from the mold. This is an additional measure that relies a lot on the right timing, since quick cooling reduces the material too quick, causing warping of the product.
4. The unloading or de-moulding phase.
As soon as the component within te mold has cooled adequately, the person managing the operation can then take out the finished item from the mold. The function is repeated from the beginning, providing a number of identical product lines.
For more information on the different rotational molding options offered for the Rockford TN 37853 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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