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Rotational molding pertains to a plastic production procedure that makes hollow stress-free product lines. The method relies on high temperatures and bi axial rotation to come up with seamless, one piece products that have several forms, sizes and colors. This technique is also referred to as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The feature that makes this different from other plastic manufacturing processes that no pressure is needed. It also has few rivals when it involves the creation of large size hollow items which are long-lasting and inexpensive.There is a wide variety of product lines that are generated by this process including big water tanks, automobile products, sophisticated molded medical items, recreation equipment, toys, kayaks, industrialized equipment among many others.This is due to the versatility in regards to design and shapes that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Leakey TX 78873, 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 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 Leakey 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 Method in Detail
This moulding system has been used since early times for creatingvseverl products. Egyptians for instance, employed rotational molding systems in the making of ceramics. The Swiss were also utilizing this rotation type to generate hollow chocolate eggs. Some plastic products in the USA were manufactured using this procedure some time between 1940 and 1950. Given that it was viewed to be a rather slow-moving system, the process has however taken long to catch on
1. Mould preparation.
A predetermined measure of polymer in powder form is filled into a hollow mould. The mould is usually comprised of cast aluminium or sheet steel material. The color desired 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 format of plastic assembly.
Preheating 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 mould with the powdered polymer is then sealed and put into the oven.
2. The heating up and fusion process.
Once inside the oven, the mold is revolved on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mold. The spinning is done slowly, about 20 spins per minute. Something that is vital at this point is the amount of time the mold will spend within the oven. If it overstays, the material will lose stability and durability, generating a poor product. If it is taken out from the oven prematurely, the polymer will not have flowed correctly, which produces 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 removed for cooling. This may be done by air or water, or sometimes a mixture of both which generates a cool mist. When the product cools, it shrinks somewhat for ease of extraction from the mould. This is one more step that depends upon a lot on the correct timing, since quick cooling shrinks the material too rapidly, causing warping of the product.
4. The discharging or de-moulding phase.
As soon as the component inside te mould has cooled effectively, the person handling the operation can then extract the completed product from the mold. The function is repeated from the start, making a number of similar products.
For more information on the different rotational rotomolding options offered for the Leakey TX 78873 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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