As an investor, it may seem challenging to choose the right plastics manufacturing process for your projects. It’s due to the many options available in the market today. Rotational molding is one of the most cost-effective and efficient methods at your disposal.
So, what is roto molded plastic? It’s a sturdy and smooth-surfaced plastic element produced through the rotomolding process, ideal for various applications. Here is a guide to rotational molding covering the technology involved and other useful information.
What does Rotational Molding Mean?
Rotational moulding is a unique plastic design manufacturing technology that has gained massive popularity. Most companies use the technique to produce hollow objects using a shell-like mold while rotating and heating it simultaneously.
Unlike other processes, rotomolding doesn’t require the use of pressure. Therefore, it involves fewer steps that significantly lower the production cost. Objects made using this method will thus appear quite inexpensive. The operations involved gives a manufacturer the freedom to produce any item size and shape to meet specific needs.
Rotomolding will suit you best if you are looking for high quality, high stability, and uniformly thick walls in your containers. You can try it out whether you need large double-walled open containers or one-piece hollow parts.
[Learn more about: Rotational Mold Making ]
Advantages and Benefits of Rotational Molding
The rotomolding process boasts the following benefits over other comparative methods.
Its Exceptionality Efficient
The production method allows manufacturers to come up with a flexible plastic design within a short time. It’s, therefore, ideal for any company that needs its materials urgently. The casting type in roto moulding requires less tooling, thus the quick turnaround time. Besides, the manufacturers can easily swap the cast colors making the process even faster.
Since Rotomolding doesn’t require high operating pressure, it supports the use of low-cost metals like aluminum for rotomold tooling. The low initial investment makes the process ideal for small volume productions. Additionally, you can mold various pieces created through this process to come up with one part, eliminating high manufacturing costs.
The Process Results in a Consistent wall Thickening
The continuous mold rotation evenly coats all walls during the heating and cooling process.
You can Easily make other Complex Shapes
The method accommodates the manufacture of double-walled containers, inserts, and stiffening ribs with no secondary processing.
The Process Results in the Production of Highly Durable Plastic Design
The rotational molding machine casts all parts as one-piece eliminating welding lines or joints, which can create weak points. It doesn’t rely on pressure; thus, the produced objects boast high stability, which reduces the risk of any defects. The thick corners created further boost the item’s strength by minimizing failure chances.
It allows the Production of Various Surface Finishes
The soft metal used during rotomolding supports surface polishing like lettering, use of symbols, or logos.
The Entire Process Significantly Contributes to Environmental Sustainability
Their high durability ensures that the production takes place once over a long time. It also reduces the freight costs thanks to their lightweight nature and high portability. Additionally, the rotational molding procedure results in minimal waste. Even better, you can recycle the waste products for future production.
What are some Rotational Molding Applications?
The rotomolding machine can make different plastics sizes and shapes. Therefore, the processes benefit various sectors, including the automotive, agricultural, construction, and water industry. Additionally, many furniture, packaging, water treatment, marine, sports, and leisure companies use rotational moulding products.
You will always find these items during your day to day activities. Some rotational moulding uses include the manufacture of containers and bins used to ship or store goods conveniently. Using a rotational moulding machine, manufacturers come up with different colors and sizes of bulk plastic storage containers. Mostly, food processing or material handling companies use these receptacles.
The manufacturing method also contributes to the production of various vehicle auto parts. They range from external design elements like the cup holders, mudguards, and other essential mechanical parts.
Moreover, the process results in the production of various road barriers, signs, cones, bollards, and traffic dividers. Using the custom rotational molding process, you can create a wide range of toys and trinkets. Besides, it manufactures most playground materials from Ping-Pong balls to some pool tables.
One industry that relies on rotational moulding is sports. The manufacturing process produces various vessels used in kayaking, boating, canoeing, and surfing. Besides, it applies in the production of golf carts, dumbbells, helmets, among many. Further, it contributes significantly to the creation of storage tanks for commercial, industrial, and agricultural purposes.
The process manufactures a wide range of industrial parts, including tote bins and covers among many. Moreover, by using the method, you can manufacture baby coats and mannequins.
The Production Process of Rotational Molding
You are probably asking, “how does rotational moulding work?” Well, the process begins by loading a powdered plastic material, mostly polyethylene, into a hollow mold. The manufacturer then places the cast in a rotomolding machine with temperature ranging between 260°C – 370°C based on the material.
The mold then slowly rotates in both a vertical and horizontal axis. Afterward, the polymer melts gradually and adheres to the mold’s inner surface. The final step involves cooling the molten material by using a fine mist of water or air. Once it adequately solidifies, you can now unload the formed object.
Repeat the procedure as much as required, and if any mold splits appear, remove it via trimming. It would be best to subject the objects to leak tests to check on the quality. At this juncture, you can also add some holes, screws, and slots where necessary.
The Materials used in Rotational Molding
All materials used in the rotational molding machine requires sufficient resistance to oxidation, high thermal stability, and ductility. Today, the process heavily depends on polyethylene since it’s readily available and easily moldable. During the manufacturing process, you will require high-density polyethylene. It supports complex design in great products, especially those used in the food manufacturing industry.
Besides, the process also involves the use of linear low-density polyethylene. The material offers high impact resistance in tanks, toys, containers, and other outdoor recreational equipment. Additionally, you may need to use polypropylene since it has a high melting point and resistance to stress.
Besides, the static –dissipative polyethylene also works best in electrical applications to prevent potentially hazardous charges. Another essential element is the cross-linked polyethylene that adds considerable strength to the molding process. Still, the objects may contain other components like PVC plastisols, nylon, and acetal. During the manufacturing process, the rotomolding machine used includes a mold spindle, an oven, and a cooling chamber.
Why work with Roto Dynamics
By entrusting your projects to Roto dynamics, you will enjoy innovative rationally molded plastic products. Further, you have a chance to ask for some creative designs to meet industry-specific needs. You can also request for a range of smooth textured finishes to enhance your final product’s appearance.
Roto dynamics can make a wide range of products used in various sectors. Besides, you will receive your items within the shortest time possible. You will love the plastic components’ look and feel, thanks to the latest rotomolding machine and quality materials used.
The above informative guide aims at shedding some light on rotational molding processes to help you make an informed decision. It’s a unique and cost-effective technique that produces hollow plastics suitable for a wide range of applications.