What is rotational moulding?
Rotational moulding offers distinct design advantages over other moulding processes. Rather than having to manufacture and then assemble a number of different parts, with rotational moulding a product can be moulded in one piece as a whole product, eliminating high fabrication costs.
The process also has unique design strengths, such as consistent wall thickness and strong outside edges which are seamless and almost totally stress free. As one of the original innovators of the rotational moulding process, Corilla has perfected the design and manufacturing process.
A step-by-step guide to the rotational moulding process:
- A mould is created according to the specifications for the finished product.
- If any metal inserts are to be moulded in, they are fitted to the mould.
- A measured amount of the appropriate polymer powder is added to the mould.
- The mould is securely closed.
- The mould is heated and rotated simultaneously about two axes mutually at right angles. During this part of the process the polymer is distributed evenly around the interior of the mould, gradually adhering to it.
- The mould is cooled.
- The component is unloaded from the mould, ready for finishing.
Benefits of Rotational Moulding
There are a number of reasons why the rotational moulding process is the obvious choice
Cost:
- Tooling: Can be less than 1/5th of injection and blow moulding alternatives
- Piece Part: Lower cost for low to medium production runs
- Material: Can often be used to replace expensive incumbent steel alternatives
Quality:
- Repeat: Consistent repeatability and accuracy of component
Versatility:
- Range: Wide range of components across diverse industry sectors.
- Size: Small to large components
- Shape: From simple to complex shapes providing strength and durability
- Finish: Variety of finishes from smooth polished to textured
- Speed: Overall lead time shorter versus other processes
Environmental:
- Impact: Less environmental impact due to recyclability of plastic material
Design Considerations
The design benefits of using our rotational moulding processes include:
- An absence of complex mould split lines
- Male or female moulded threads
- Moulded-in inserts
- Moulded in Graphics
- Side cored undercuts
- Wall thickness from as little as 2mm upwards
- Twin wall products
- Multi layer products that can be made from different polymers
- A large range of surface finishes: textured using mechanical application or etching, smooth, polished – or a combination.
- Hollow shapes can also be cut in half after moulding to create two parts
- Cut-outs, holes, and slots can be formed and assemblies built up from separate mouldings with combinations of bought-in components
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