How to Know if Rotational Molding is Right for You
Rotational molding — also referred to as rotomolding — is a common manufacturing process used to create large, hollow products. Because of its versatility, it can be used to create everything from storage tanks to playground equipment. In fact, so many companies rely on this process that the industry is expected to surpass $9 billion by the end of 2033. If you’re considering using the rotational molding process for your business, you might be wondering what it entails. Here, we’re breaking down all the steps so you can make an informed decision for your business.
1. Design and Prototyping
The first step in the rotational molding process is to have a design meeting with your chosen partner. The engineering team will get to know your needs, then develop a design using a CAD software. This allows the design professionals to get the right dimensions, features, and material requirements in the most efficient manner.
Once the design is approved, it will enter the prototyping stage. Here, the design is tested, many times using a small-scale mold. If the product emerges with any defects, the engineering team will work to correct them until it meets specifications.
2. Mold Design and Fabrication
When the prototype has finished going through the approval phase, it’s time to move on to the final mold design and fabrication. The final mold will be designed and created using precision manufacturing techniques like CNC machining. This way, you can be sure your parts will be made to the proper specifications every time.
3. Production
During the production process, a plastic polymer will be 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. These are the steps you can expect in that process:
- Mold loading: a technician measures a specific amount of polymer powder into the mold. Usually, this will be a polyethylene substance. It’s possible to use other polymers, but polyethylene is favored for its excellent melt flow properties, and resistance to impact, chemicals, and UV rays.
- Heating: the mold will then be heated as it rotates along both horizontal and vertical axes, causing the plastic to melt and coat the interior surface of the mold.
- Cooling: once the molten plastic has covered the entire mold, it’s cooled to solidify and set the desired shape. This process is usually done using air or water.
- Product extraction: the final step in this process is to extract the product from the mold. In some machines, the mold halves separate, allowing for easy removal of the product. In other cases, there might be additional mechanisms or tools to aid in the extraction process.
At GVL Poly, we use a Leonardo Smart Molding Machine to increase efficiency during the rotational molding process. In fact, we were the first custom rotational molder in North America to operate this machine. Learn more about the benefits of our investment in this machine here.
Post-Processing
In many cases, the part will need secondary processing before it can be shipped to the final destination. These secondary processes might include trimming excess material from the part, sanding, or other finishing processes.
Quality Control and Testing
The final part of the rotational molding process is to ensure the part goes through quality control and testing. The manufacturing team will perform agreed-upon checks to ensure the part meets all design specifications and standards.
Work with GVL Poly for Your Rotational Molding Needs
For businesses seeking expertise in the rotational molding process, GVL Poly stands out as a reliable partner. Founded in 1992, we have over 30 years of experience helping companies like yours get the best products possible. Our services are backed by experienced machine operators, engineers, designers, tool builders, and other professionals. When you need high-quality parts, trust us to provide them.
Let’s Get Started
Want to learn more about what we can do for you? Reach out to our team for an initial consultation.
