December 8, 2022

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Factors to consider while designing your product for rotational modeling

What is meant by rotomolding?

If you wish to produce a plastic component that is hollow and rounded, you can consider going for a rotational molding process. The act of producing hollow plastic components with a rotating mold and some heat energy is known as rotomolding. Rotomolded plastic products can find several applications across various areas, from engineering to household usage. The process of rotomolding is as below,

  • The powder polymer is poured into the mold.
  • The mold starts rotating, and the heat is applied.
  • The powder becomes fused to coat along the walls of the machine.
  • The machine will go for cooling and solidification of the polymer.
  • The demolding process will give the final product.

Although the process seems simple, you should consider some factors before you finalize your product design. Let us discuss these in this article.

Flat surfaces

You are going to do rotational molding, and the name suggests that the product will not be flat. Since the process involves the constant rotation of the mold, it will be difficult or impossible to attain a large flat surface in your product. So, you should keep this in mind before starting to design your product. You can try to avoid these kinds of designs and try to make the flat surfaces slightly curved or deformed by adding or removing some parts of it.

Material bridges

The process is completely rotational, and you should consider the capacity of the material to flow throughout the mold seamlessly. If you have walls or ribs in the products, you should design them such that there is more gap between them. Once you design them closely below five-millimeter thicknesses between them, the powdered polymer will bridge between them, and you will not get the end product right. So, it is vital to consider this material bridges in the design stage of production.

Sharp corners

It is similarly tedious to produce products with sharp edges as it is to get flat surfaces in the end. Since the product is made of rotation of the mold, a sharp edge will be impossible in most of the cases. If you design a sharp edge in your product, there will be some restrictions on the movement of the material inside the mold during rotation. Due to this hindrance for the material to move freely, there will be some voids in other parts of the coating. So, your final product will not be of better quality. If there is a sharp corner in your mold, there will be heat accumulation at the point, and there may be deterioration in the wall thickness of your product. Some areas will be thicker, and some will be lighter.

The final look of the product

It is vital to consider the final look of the product as per your client’s requirement in the design phase. The rotational molding process will create products with accuracy and a better aesthetic as per your design. So, if you miss some considerations in your design phase, you will lose that in the final output, and your clients may get disappointed.