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This article presents all the information you need to know about rotational molding. Read further and learn more about the following:
Overview of rotational molding and its history
Types of rotational molding machines
Rotational molding processes
Materials used in rotational molding
And much more...
Chapter 1: Rotational Molding
Rotational molding, commonly referred to as "rotomolding", is a plastic casting technique used to produce large hollow, seamless, and double-walled parts. It is a three-stage process that involves a mold on a rotating frame, a heating chamber, and a cooling chamber. Molds for the rotomolding process are specially designed and are capable of producing single and double wall products.
The main raw material for rotomolding is one of the polyethylene resins, which is loaded into the mold to begin the process. In the heating chamber, the mold is rotated as it is heated. The frame of the mold is capable of rotating the mold to every point of its rotational axis. As the mold rotates, the resin is spread over the interior surface of the mold giving the finished product an equal and even thickness across its surface.
After a set period of time, the mold moves from the heating chamber to the cooling chamber, where the liquified melted resin is allowed to cool before the plastic product is ejected from the mold. Rotationally molded products are of the highest quality and are known for their durability and strength.
Rotational molding is a non-pressure molding process, which makes the toolings of the molds less expensive since they do not have to endure the stress of being pressured. The sizes for rotationally molded products are limitless since the molds and equipment are capable of creating very large complex plastic shapes. There are also few restrictions when it comes to part design, giving the designer freedom to add complicated details.
Included in the products produced by rotational molding are kayaks, sports helmets, display mannequins, water storage tanks, baby cribs, and barriers for road construction. All of these large plastic products can be easily produced using rotational molding at less expense and with great efficiency.
The rotational molding process has been traced back to the ancient Egyptians, who created ceramics hundreds of years ago. The first application of a more advanced rotational molding process was the production of artillery shells in 1855 and hollow chocolate eggs by the Swiss in 1910 to create a uniform wall thickness and density. In these periods, there were several patents registered to document the nature of this casting process. However, it was regarded as a slow process, and some challenges were encountered, leading to the process not being popularized
Effectively evaluate, optimize and communicate your product design with concept models. Used in early stages of product development, models from Raystreak's Proto Poly reduce costs and shorten development timelines.
With a physical model you can easily communicate, evaluate and optimize your product design. 3-D production system gives you the ability to quickly produce physical models without the time and cost associated with machining or outsourcing. This allows you to review multiple designs quickly, test form and fit to solve design problems early, and create numerous iterations to improve the final product design.
How are concept models used?
Function, Form and Fit testing
Communication models between departments and companies
Product research
How are models built?
3-D Production Systems are powered by Fused Deposition Modeling (FDM) Technology, which is simple and safe. They manufacture parts layer-by-layer in durable production-grade thermoplastics that really hold up.
Pre-Process: Load the part’s STL file (CAD data) into Insight pre-processing software.
Manufacture Parts: System builds part in thermoplastic material one layer at a time on precise tool paths.
Remove Supports: Remove temporary support structures in a hands-free soluble support tank.
Optional – Finishing techniques like painting, electroplating and wood grain dipping can be applied to make the prototype look like a final production piece.
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