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Rotational molding pertains to a plastic production solution that generates hollow stress-free products. The procedure depends on high temperatures and bi axial rotation to follow up with seamless, one piece items that have a wide range of designs, colors and sizes. This procedure is also referred to as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The function that makes this unique from other plastic manufacturing techniques that no pressure is needed. It also has few contenders when it comes down to the production of large hollow items which are long-lasting and inexpensive.There is a variety of product lines that are created by this process including large water tanks, automobile products, sophisticated designed medical products, recreation equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of 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 Converse TX 78109, 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 Texas 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 Converse Texas 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 Procedure Components
This molding process has been used since ancient times for creatingvseverl products. Egyptians for example, worked with rotocasting systems in the manufacturing of ceramics. The Swiss were also utilizing this rotation technique to generate hollow chocolate eggs. Some plastic items in the USA were developed using this technique some time between 1940 and 1950. Because it was regarded to be a somewhat slow technique, the technique has however taken long to become popular
1. Mould prep work.
A fixed amount of polymer in powder form is filled into a hollow mould. The mold is usually crafted from cast aluminium or sheet steel component. The coloring wanted 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 design of plastic production.
Pre-heating 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 positioned into the oven.
2. The heat and fusion procedure.
Once inside the oven, the mold is rotated on two axis so the powdered polymer melts from the heat and layers the inside if the mould. The rotation is done gradually, about 20 rotations per sixty seconds. The main thing that is important at this moment is the amount of time the mould will spend inside the oven. If it stays to long, the material will lose stability and durability, producing a faulty item. If it is removed from the oven too early, the polymer will not have liquefied properly, which develops bubbles in the finalized item.
3. Mould cooling down.
When the component has sufficiently 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 reduces slightly for ease of extraction from the mould. This is another measure that depends a lot on the right timing, since rapid cooling reduces the material too rapidly, causing warping of the product.
4. The un-loading or de-molding step.
As soon as the product within te mold has cooled successfully, the molder taking care of the operation can then remove the finalized item from the mold. The process is repeated from the start, making a number of identical items.
For more information on the different rotational rotomolding options offered for the Converse TX 78109 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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