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

rotomolding-Great Falls-Rotational molding refers to a plastic manufacturing method that creates hollow stress-free items. The technique relies upon high temperatures and bi axial rotation to follow up with seamless, one piece products that have a wide range of shapes, colors and sizes. This procedure is also known as rotomolding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.

The benefit that makes this unique from other plastic manufacturing processes that no pressure is required. It also has few contenders when it pertains to the production of large hollow products which are long lasting and inexpensive.There is a variety of products that are produced by this process including big water tanks, automobile items, complex designed medical items, recreation equipment, toys, canoes, commercial equipment among many others.This is due to the versatility in regards to design and shapes that the process creates

Benefits of Using Rotomolding to Manufacture Plastic Products

  • Relatively low tooling costs.
    When compared to other plastic manufacturing processes in Great Falls VA 22066, 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 rotomolding 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-Great Falls-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 Great Falls 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 Rotomoulding Process in Detail

This moulding method has been used since early times for creatingvseverl items. Egyptians for instance, applied roto-molding techniques in the creating of ceramics. The Swiss were also making use of this rotation design to create hollow chocolate eggs. Some plastic items in the USA were manufactured using this approach some time between 1940 and 1950. The process has however taken long to take affect because it was considered to be a relatively slow process

1. Mould preparation.
A predetermined amount of polymer in powder form is loaded into a hollow mould. The mould is usually made from cast aluminium or sheet steel substance. The color preferred for the end product is pre compounded into the polymer. The most often used powder resin is polythene, but polyvinyl chloride and nylon can also be used in this style of plastic assembly.

Pre-heating of the oven follows, 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 inserted within the oven.

2. The heating and fusion step.
Once inside the oven, the mould is spun on two axis so the powdered polymer melts from the heat and coats the inside if the mould. The spinning is done gradually, about 20 rotations per min. Something that is crucial at this point is the period of time the mold will spend within the oven. If it stays to long, the component will lose value and strength, creating a poor product. If it is removed from the oven too early, the polymer will not have melted properly, which develops bubbles in the finalized product line.

3. Mould cooling.
When the component 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 creates a cool mist. When the product cools, it shrinks a little for ease of extraction from the mold. This is yet another measure that depends upon a lot on the correct timing, since rapid cooling decreases the material too quick, causing warping of the item.

4. The un-loading or de-moulding step.
When the component inside te mould has cooled properly, the molder managing the process can then take out the finalized item from the mould. The procedure is repeated from the beginning, making a number of similar items.

For more information on the different rotational rotomolding options offered for the Great Falls VA 22066 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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