Rotomolding Inc

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Rotational Molding Comes Of Age As Product Developers Understand Its Strengths, Seek Low Initial Cost Sept. 28th, 2005 By Robert Dunne Now that product design and development engineers better understand rotational molding's impressive range of inherent strengths compared to even a few short years ago, they have been confidently specifying the process in ever greater numbers. After stellar growth during the mid-1990's, the rotational molding industry appeared to reach its peak by 2001 as the toy industry moved overseas and the 9/11 recession rippled through the economy, according to Dr. Peter J. Mooney of Plastics Custom Research Services, Advance, NC. Today, after a modest recovery, more than 1,700 rotational molders operate worldwide and tallying the annual tonnage of material used is now done in billions in the Americas alone, according to a 2003 report from the Association of Rotational Molders. Rotational molding delivers consistent wall thicknesses, sturdy corners and structural strength even with complex, hollow and multi-wall parts in odd shapes and configurations. Its ability to seamlessly achieve nearly any shape in tight tolerances provides product designers with the flexibility to create exactly what they envision without compromising their designs. These advantages have established rotational molding as the obvious choice for producing chemical and fuel tanks, bulk containers, kayaks, carts, housings, point-of-purchase displays and other products. A diverse range of materials including nylons, metallocenes and cross-linkable polyethylenes may be rotationally molded, in addition to the more commonly used polyethylenes, polypropylenes and PVC. A host of additives for meeting FDA requirements, fire resistance and controlling static are also available. Since the process relies solely on heat and smooth rotation for melting and forming (without high pressures), the mold doesn't have to withstand the pounding required of injection molding and other processes. That's why rotational molding tooling often costs 50 - 80% less than a comparable tool used for injection or blow molding. This low initial cost minimizes the risk in bringing new products to market and often makes producing small quantities cost-effective, compelling reasons for product developers to consider rotational molding. This advantage vs. other materials has driven experienced rotational molders to become skilled in recognizing opportunities to convert existing products from metal, wood and fiberglass into plastic. Multiple parts and components are often redesigned into a single, rotationally molded part delivering increases in strength and structural integrity while eliminating assembly steps and secondary operations. As the cost of steel continues to rise along with the cost to assemble fabricated metal parts and its shortcomings vs. plastic become more apparent, these conversions will become even more prevalent. Further, each conversion yields a product that likely will never again be produced with anything but plastic.

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