Build Stronger, Longer-Lasting Parts with Smarter Design Choices
Rotomolded parts are known for their durability. However, incorrectly made parts can crack, warp, or fail under pressure. This can lead to downtime, frustrated customers, and a smaller profit margin for your business. Luckily, most failures can be traced back to the design phase. When you implement a few rotomolding design guidelines, you can dramatically improve the durability of your parts. Below, we’re outlining five things you can do today to improve your parts’ overall performance.
What is Rotomolding?
Before we talk about rotomolding design guidelines, let’s define the process. Rotational molding is a highly specialized manufacturing method that’s used to create everything from storage tanks to playground equipment. It involves using a pre-manufactured mold to shape a plastic polymer. The plastic material is heated inside the mold, which is then spun around two perpendicular axes. The polymer then coats the inside of the mold, which creates a tight-tolerance, hollow part.
So many organizations rely on this process that the industry is expected to surpass $12 billion by 2037. Overall, it offers customization, flexibility, and durability that just can’t be matched. But if products aren’t made correctly, they could fail under pressure. That’s why paying attention to rotomolding design guidelines is so important.
Optimize Wall Thickness for Strength and Durability
Inconsistent wall thickness can create stress points, leading to premature failure. Optimizing wall thickness can greatly improve your parts’ durability. An experienced rotomolded part manufacturer will use proper draft angles and parting lines to avoid potential issues. Additionally, they will avoid using deep, narrow sections to ensure even wall distribution.
Use Rounded Corners to Reduce Stress
Sharp angles look clean on a CAD model. But in real life, they’re just stress concentrators. If your part flexes or takes an impact, sharp corners become weak points where cracks can start. That’s why an experienced rotomolding partner will design with large, rounded transitions. This ensures that loads are distributed evenly across the part, improving structural integrity.
Choose the Right Material for the Application
When creating a rotomolded part, you can choose from a wide range of materials. Each will have its advantages and disadvantages, which you’ll have to weigh. For example, high-density polyethylene (HDPE) might be perfect for impact resistance. On the other hand, cross-linked polyethylene (XLPE) could be better for chemical exposure. It’s always best to talk to an experienced rotational molding manufacturer to determine what’s best for you.
Design for Consistent Cooling and Shrinkage
Within the rotomolding process, the part must cool inside the mold. If the cooling isn’t uniform, the part can warp, crack, or develop internal stresses. Your rotational molding partner should use venting to promote airflow, avoid large differences in wall thickness, and think carefully about part geometry to allow even heat distribution.
Account for Real-World Use in the Design
The best designers think about the real-world uses of the parts. How will they be handled, mounted, stored, cleaned, or transported? What will the impact zones and potential wear points be? What kinds of loading scenarios and environmental exposures will they be subject to? Great design will take those considerations into account.
Want More Information on Rotomolding Design Guidelines? Reach Out to GVL Poly
If you have questions about rotomolding design guidelines, we’re here to help. For over 30 years, we’ve been creating the best rotomolded parts for our customers, ensuring they meet the highest standards. Over the years, we’ve helped countless businesses get the right fit for their organization. We’d be honored to help you, too.
At GVL Poly, we’ll handle your project from start to finish. Our in-house team can handle everything from design and rapid prototyping to fabrication and logistics. All our services are backed by experienced machine operators, engineers, designers, tool builders, and other professionals. Additionally, we invest in the highest quality machinery possible. In fact, we were the first company in North America to have a functional Leonardo SMART Molding Machine.
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Are you ready to start your next rotomolding project? We’d love to answer any questions you may have. Get in touch with us here.
