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Rotational moulding pertains to a plastic production procedure that creates hollow stress-free products. The function utilizes high temperatures and bi axial rotation to come up with seamless, one piece items that have varying forms, colors and sizes. This procedure is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl styles.
The benefit that makes this different from other plastic manufacturing techniques that no pressure is needed. It also has few rivals when it involves the creation of sizable hollow items which are resilient and inexpensive.There is a wide variety of product lines that are generated by this process including big water tanks, automobile items, intricate designed medical products, recreation equipment, toys, canoes, industrialized equipment among many others.This is because of the versatility in terms of type and forms that the process produces
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Spring Branch TX 78070, 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 Spring Branch 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 in Detail
This moulding process has been used since earlier times for creatingvseverl items. Egyptians for instance, utilized rotomoulding procedures in the creating of ceramics. The Swiss were also using this rotation method to generate hollow chocolate eggs. Some plastic product lines in the USA were made utilizing this method some time between 1940 and 1950. The system has however taken very long to catch on because it was looked at as being a somewhat slow-moving process
1. Mould readying.
A fixed volume of polymer in grain form is loaded into a hollow mould. The mould is usually made of cast aluminium or sheet steel component. The colour intended 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 type of plastic production.
Pre-heating of the oven starts, and it may 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 installed into the oven.
2. The heating and fusion phase.
Once within the oven, the mould is rotated on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The turning is done gradually, about 20 spins per sixty seconds. The main thing that is crucial at this moment is the amount of time the mould will spend within the oven. If it overstays, the material will lose value and durability, generating a poor item. If it is taken out from the oven prematurely, the polymer will not have liquefied properly, which produces bubbles in the finalized item.
3. Mold cooling down.
When the product has completely spent the correct amount of time in the oven, it is then removed for cooling. This can be done by air or water, or sometimes a mixture of both which a cool mist. When the material cools, it shrinks a little for ease of removal from the mould. This is one more procedure that relies a lot on the correct timing, since quick cooling shrinks the material too quickly, causing warping of the item.
4. The unloading or de-molding step.
Once the product inside te mould has cooled correctly, the molder handling the procedure can then remove the finalized item from the mold. The process is repeated from the start, providing a series of similar product lines.
For more information on the different rotational rotomolding options offered for the Spring Branch TX 78070 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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