Looking for rotational molding alternatives for Virginia? Want affordable custom plastic molding that is cost effective for Berryville area? Then give us a call at our toll free number 866-971-7861 or request a quote today!

rotational molding-Berryville-Rotational molding refers to a plastic manufacturing method that generates hollow stress-free product lines. The procedure relies upon high temperatures and bi axial rotation to come up with seamless, one piece objects that have different forms, sizes and colors. This technique is also called rotomoulding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.

The attribute that makes this different from other plastic manufacturing processes that no pressure is involved. It also has few contenders when it pertains to the production of large size hollow products which are durable and inexpensive.There is a wide range of items that are developed by this process including large size water tanks, automobile materials, intricate molded medical products, recreation equipment, toys, canoes, industrialized equipment among many others.This is due to the flexibility in regards to 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 Berryville VA 22611, 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

Plastic Molding-Berryville-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 Virginia 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 Berryville Virginia 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 Roto-Molding Method in Detail

This moulding technique has been used since early times for creatingvseverl products. Egyptians for instance, used rotocasting techniques in the of ceramics. The Swiss were also making use of this rotation technique to make hollow chocolate eggs. Some plastic product lines in the USA were created utilizing this technique some time between 1940 and 1950. The system has however taken very long to catch on because it was thought of to be a moderately slow process

1. Mould readying.
A fixed measure of polymer in particle form is filled into a hollow mould. The mold is usually composeded of cast aluminium or sheet steel component. The colour chosen for the finished 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 format of plastic assembly.

Preheating of the oven follows, and it may be done by either conduction, convection or sometimes radiation. It is warmed to temperatures between 500-700F. The mould with the powdered polymer is then locked and installed into the oven.

2. The heat and fusion procedure.
Once inside the oven, the mold is rotated on two axis so the powdered polymer liquefies from the heat and layers the inside if the mold. The turning is done gradually, about 20 spins per min. Something that is critical at this point is the period of time the mould will spend inside the oven. If it stays to long, the product will lose stability and durability, creating a poor item. If it is taken out from the oven prematurely, the polymer will not have liquefied correctly, which produces bubbles in the completed product.

3. Mold cooling down.
When the material has sufficiently spent the right amount 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 a cool mist. When the product cools, it shrinks a little for ease of extraction from the mould. This is yet another measure that depends upon a lot on the correct timing, since quick cooling reduces the material too rapidly, causing bending of the product.

4. The unloading or de-molding step.
As soon as the component inside te mold has cooled effectively, the molder managing the process can then extract the finalized product from the mould. The function is repeated from the beginning, making a series of identical products.

For more information on the different rotational rotomolding options offered for the Berryville VA 22611 area, please call our toll free number  866-971-7861 or fill out the form on the right for a consultation!

Other areas we service, go here to plastic products

Local Resources

Production Example
Google Map