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

rotocasting-Boyceville-Rotational molding refers to a plastic manufacturing method that creates hollow stress-free product lines. The technique uses high temperatures and bi axial rotation to follow up with seamless, one piece objects that have a wide range of designs, colors and sizes. This procedure is also known as rotomoulding or rotocasting. Sometimes the term slush molding is used for certain liquid vinyl types.

The benefit that makes this unique from other plastic manufacturing procedures in that no pressure is involved. It also has few rivals when it comes to the manufacture of large hollow products which are durable and inexpensive.There is a wide range of products that are generated by this process including large size water tanks, automobile items, intricate designed medical products, leisure equipment, toys, canoes, industrialized equipment among many others.This is because of the versatility in terms of type and forms that the process creates

Benefits of Using Rotomolding to Manufacture Plastic Products

  • Relatively low tooling costs.
    When compared to other plastic manufacturing processes in Boyceville WI 54725, 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

Custom Molded-Boyceville-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 Wisconsin 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 Boyceville Wisconsin 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 Components

This molding operation has been used since ancient times for creatingvseverl product lines. Egyptians for instance, applied roto-molding solutions in the of ceramics. The Swiss were also making use of this rotation format to generate hollow chocolate eggs. Some plastic products in the USA were made using this method some time between 1940 and 1950. Given that it was considered to be a relatively slow-moving system, the procedure has however taken long to catch on

1. Mold fitting.
A predetermined amount of polymer in particle form is filled into a hollow mold. The mold is usually constructed from cast aluminium or sheet steel component. The color tone desired for the final item 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 design of plastic manufacturing.

Pre-heating of the oven starts, and it can be done by either conduction, convection or sometimes radiation. It is heated to temperatures between 500-700F. The mold with the powdered polymer is then secured and installed into 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 overlays the inside if the mold. The turning is done gradually, about 20 revolutions per sixty seconds. One thing that is critical at this point is the period of time the mold will spend inside the oven. If it overstays, the product will lose stability and durability, generating a faulty item. If it is extracted from the oven too early, the polymer will not have melted properly, which generates bubbles in the finished product line.

3. Mould cooling down.
When the product has sufficiently spent the correct 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 creates a cool mist. When the product cools, it shrinks slightly for ease of extraction from the mold. This is one more procedure that depends a lot on the correct timing, since rapid cooling decreases the material too fast, causing bending of the material.

4. The offloading or de-moulding step.
Once the product within te mold has cooled adequately, the person taking care of the procedure can then extract the finalized product from the mould. The function is repeated from the beginning, giving a number of identical products.

For more information on the different rotational molding options offered for the Boyceville WI 54725 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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