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Rotational molding pertains to a plastic production procedure that makes hollow stress-free product lines. The method depends on high temperatures and bi axial rotation to come up with seamless, one piece objects that have varying shapes, sizes and colors. This method is also referred to as rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The benefit that makes this different from other plastic manufacturing procedures because no pressure is called for. It also has few competitors when it comes to the manufacture of sizable hollow products which are long lasting and inexpensive.There is a wide variety of products that are developed by this process including big water tanks, automobile products, complex molded medical items, leisure equipment, toys, kayaks, commercial equipment among many others.This is due to the flexibility in terms of style and forms that the process manufactures
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Dawson TX 76639, 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 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 Dawson 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 Process in Detail
This moulding process has been used since early times for creatingvseverl items. Egyptians as an example, used rotomoulding methods in the making of ceramics. The Swiss were also applying this rotation method to make hollow chocolate eggs. Some plastic products in the USA were developed using this technique some time between 1940 and 1950. Given that it was considered to be a fairly slow method, the method has however taken long to catch on
1. Mold prep work.
A predetermined volume of polymer in particle form is loaded into a hollow mould. The mould is usually constructed from cast aluminium or sheet steel component. The color desired 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 design of plastic production.
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 locked and put within the oven.
2. The heating and fusion procedure.
Once inside the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and layers the inside if the mould. The turning is done slowly and gradually, about 20 revolutions per sixty seconds. One thing that is important at this moment is the period of time the mold will spend within 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 too early, the polymer will not have melted correctly, which develops bubbles in the finished product.
3. Mould cooling down.
When the product has completely 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 generates a cool mist. When the component cools, it reduces a little for ease of extraction from the mould. This is an additional step that depends a lot on the ideal timing, since rapid cooling shrinks the material too rapidly, causing warping of the product.
4. The offloading or de-moulding phase.
Once the product inside te mould has cooled adequately, the molder managing the procedure can then remove the finished product from the mould. The process is repeated from the beginning, giving a number of identical products.
For more information on the different rotational rotomolding options offered for the Dawson TX 76639 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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