Plastic Rotational Molding

Plastic Rotational Molding

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Plastic Part Rotational Molding Services

We design, develop & manufacture rotationally molded products for a diverse array of applications in the commercial, construction, agricultural, industrial, materials handling, marine, recreational vehicle and toy manufacturing industries. Rotational molding offers consistent wall thickness, strong and durable corners, high structural strength and extremely tight tolerances – even in complex, hollow or multi-walled products, or in parts with unusual shapes or unique configurations.

And, because rotational molding allows the molding of virtually any shape – while still maintaining tight tolerances – the most unique or complex designs can be accomplished without compromising your design vision. Rotational molding can be used for even the tiniest parts. However, rotomolding is also excellent for manufacturing large parts at a lower cost. The bigger the part, the bigger the cost savings you will experience with rotational molding.

We also offer high-intensity color blending to provide custom colors for your rotational molded part. The virtually unlimited variety of color, texture and finish options available with rotational molding can add style, visual appeal or branding opportunities to any product or part. Because the rotomolding process is more cost-effective than other molding processes, there is  also less financial risk in bringing a new product to market. Because rotational molded plastic can be manufactured into virtually any shape, size or degree of complexity we can make your creative design concepts a reality when other manufacturing processes cannot.

Rotational Molding Design

Rotational molding design has three basic requirements. First, the plastic part must meet the application’s end-use or functional requirements. Second, the design of the part must account for any limitations that are related to materials or processing. Third, the rotomolded part must be cost-effective to produce.

For design engineers, the details of a part’s design can mean the difference between success and failure. Typically, these details include:

a. Nominal wall thickness
b. Wall thickness uniformity
c. Varying wall thickness
d. Flatness considerations
e. Minimum wall separation
f. Corner angle limits
g. Reinforcing ribs
h. Kiss off ribbing
i. Draft angles
j. Corner Radiuses
k. Undercuts
l. Tolerances

Production Equipment for Roto Molding Services

FacFox uses Ferry Rotospeed RS-220 and RS2-3300 machines to manufacture your custom rotomolded parts. Each machine has offset arms, and the largest machine has up to 125” swing.  This means we can rotomold plastic parts in a wide ranges of sizes and shapes from intricate spray manifolds to small boats.

Auxiliary Equipment for Roto Molding Services

High-Intensity Mixing

FacFox’s auxiliary equipment for rotomolding includes a Ribbon/Paddle Blender with a 1000-lb. capacity. Our newest machine, a high-intensity mixer with a capacity of 300 lbs., provides even faster mixing cycles and features an optimized vortex for heat generation and shear to avoid agglomeration of the mix material. This new machine “polishes” the resin, which means more uniform colors, reduced porosity and improved overall physical properties.

Polyurethane Foam Filling

FacFox also has the equipment and expertise to fill your custom rotomolded parts with polyurethane foam, which provides additional rigidity and thermal insulation. Because rotomolded parts (such as coolers) have hollow cavities, their design is optimal for filling with PU foam.

 

Advantages Of Rotational Molding

Rotational Molding Lowers Weight and Increases Part Strength

Our experienced rotomolding professionals specialize in converting parts or products made from metal, fiberglass, wood or other materials into complete, fully integrated, rotationally molded plastic designs. Let our engineers show you how converting your manufacturing to plastic rotomolding from other materials can assist in reducing your product or part’s weight, increasing its strength and lowering its manufacturing cost.

Rotational Molding Lowers Initial Tooling Costs

Because rotational molding tooling costs approximately 20% to 80% less than the cost of comparable injection mold or blow mold tooling, it is also a preferred, more cost effective method for producing parts in limited quantities. This low initial cost minimizes the risk in bringing new products to market and often makes producing small quantities more cost-effective.

Rotational Molding Lower Part Count & Reduces Costs

One of the biggest advantages of rotational molding is that multiple small parts can often be replaced with just one (or a few) bigger parts. Eliminating the need for several small parts not only lowers your cost by reducing your parts count, but also eliminates the cost of the fasteners, adhesives and labor needed for assembling small parts. As the cost of assembling fabricated parts rises across the country, less assembly means greater cost savings for you.

Rotational Molding Reduces Lead Time

Rotomolding can also substantially shorten your product’s lead time because of the faster speed of tooling fabrication. Our skilled engineers and experienced rotational molding professionals can often bring a new product from concept to market in as little as four to eight weeks.

Rotational Molding Allows Increased Part Complexity

Rotational molding is also ideal for manufacturing complex parts or products that require hollow sections, double or multiple walls, or foam filling and/or hollow. And, because the rotational molding process is weld-free, there are no “seams” to compromise durability or appearance.

We Are Expert US Plastic Part Rotational Molders

Our state-of-the-art equipment – and our years of rotational molding experience – ensure that your plastic parts will always be manufactured to your exact specifications. We confidently guarantee the highest quality of rotational molding plastic products – at the best prices.

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