Whatever industry you work in, there is a strong
likelihood that plastic components play a part in the work you do. From
oil and fuel tanks to cabs for tractors and JCBs, from pipes and ducts
to medical equipment, plastic parts are everywhere. Companies are
always on the lookout for more reliable and cost-efficient ways of
mass-producing the components they need.
Rotational moulding is a
particularly cost-effective process for manufacturing hollow plastic
products. Because this process is so versatile and very little waste is
produced, costs are low compared to other plastic manufacturing
processes, such as blow moulding or injection moulding.
How the rotational moulding process works
Believe
it or not, the process which is used to create such a versatile range
of plastic products was originally developed for creating chocolate
Easter eggs. Although the technology is far more sophisticated these
days, the basic rotational moulding process remains the same.
In
rotational moulding, polymer powder is slowly tumbled in a heated,
enclosed mould. The powder melts, forming a coating over the internal
surface of the mould. The mould is cooled, allowing the polymer coating
to become solid. The mould is then opened, and an accurately shaped
plastic part is extracted.
Rotational moulding is a highly
versatile method for making a precise, stress and seam free plastic
product at comparatively low cost. The process can produce complex
shapes with controlled wall thickness in a variety of materials. It is
particularly suitable for manufacturing hollow or partially hollow
pieces.
By selecting from a range of different materials,
articles with physical properties as varied as flexible gearstick
gaiters or rigid commercial vehicle cab components can be made. Metal
inserts such as threads and bushes can be moulded in, and moulded
cavities filled with foam. Alternatively, threads may be part of the
moulded shape itself. Mouldings may be CNC machined, drilled, sawn,
routed, tapped or welded.
The appearance of the product can be
enhanced by applying a surface texture or paint. The look and feel of
other materials such as metal and leather can also be simulated. If
more rigidity or insulation are part of the design, an inner foam layer
can either be moulded integrally or injected into hollow sections after
moulding.
Rotational moulding can produce a huge variety of plastic products
The
uses for rotomoulding are extensive, stretching far beyond the basic
enclosed box or tank for which the process is best known. Rotational
moulding can produce components for machinery, furniture and fittings
for aircraft, even products for the home or garden.
By choosing
the correct polymer, tecni-form can produce articles with various
physical properties: thus the result can range from extremely flexible
- inflatable even - to very rigid and impact-resistant, such as a
protective capping.
Although a moulding starts as an enclosed
hollow shape, that does not limit the shape of the final product. For
example, the original moulding can consist of two or more combined
shapes which can then be separated to produce two or more separate
products.
As rotational moulding is such an adaptable plastic
manufacturing process, it can be used to create components for a wide
range of industries. From the automotive industry to the world of
advertising, from furniture to medical supplies, rotationally moulded
plastic products are used in most market sectors.
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