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Rotational molding refers to a plastic production solution that makes hollow stress-free items. The procedure relies upon high temperatures and bi axial rotation to come up with seamless, one piece objects that have various forms, sizes and colors. This technique is also known as roto-molding or rotocasting. Sometimes the term slush moulding is used for certain liquid vinyl types.
The function that makes this different from other plastic manufacturing techniques in that no pressure is involved. It also has few contenders when it pertains to the manufacture of sizable hollow products which are durable and inexpensive.There is a wide variety of products that are generated by this process including big water tanks, automobile items, intricate designed medical products, leisure equipment, toys, canoes, industrial equipment among many others.This is because of the flexibility in regards to design and forms that the process makes
Benefits of Using Rotomolding to Manufacture Plastic Products
- – Relatively low tooling costs.
When compared to other plastic manufacturing processes in Darrington WA 98241, 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 Washington 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 Darrington Washington 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 Rotomolding Method in Detail
This moulding procedure has been used since early times for creatingvseverl products. Egyptians for example, utilized rotational molding systems in the producing of ceramics. The Swiss were also applying this rotation type to make hollow chocolate eggs. Some plastic products in the USA were manufactured using this method some time between 1940 and 1950. The technique has however taken long to take affect because it was thought of as being a somewhat slow-moving process
1. Mould fitting.
A predetermined amount of polymer in particle form is filled into a hollow mold. The mold is usually built from cast aluminium or sheet steel material. The coloring 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 type of plastic manufacturing.
Preheating 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 mold with the powdered polymer is then secured and positioned within the oven.
2. The heating and fusion process.
Once placed into the oven, the mould is spun on two axis so the powdered polymer liquefies from the heat and overlays the inside if the mould. The rotation is done gradually, about 20 spins per sixty seconds. Something that is essential at this point is the period of time the mould will spend within the oven. If it stays to long, the material will lose value and strength, making a faulty item. If it is taken out from the oven prematurely, the polymer will not have melted properly, which develops bubbles in the finished product line.
3. Mold cooling.
When the component has sufficiently spent the right amount of time in the oven, it is then taken out for cooling. This may be done by air or water, or sometimes a mixture of both which creates a cool mist. When the component cools, it shrinks somewhat for ease of extraction from the mould. This is yet another procedure that depends upon a lot on the correct timing, since quick cooling decreases the material too fast, causing warping of the product.
4. The un-loading or de-molding phase.
Once the product inside te mold has cooled adequately, the molder managing the operation can then take out the finished item from the mould. The process is repeated from the start, supplying a number of similar product lines.
For more information on the different rotational rotomolding options offered for the Darrington WA 98241 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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