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ROTATIONAL MOLDING
Introduction
Rotational molding (also referred to as rotomolding or rotational casting) is a
unique molding process. The heating, shaping, and cooling of the plastic all takes
place inside the mold, with no application of pressure. This method dates back
to the early 1900s. Today the rotational molding industry is one of the fastest
growing segments of the plastics industry, with an annual growth of 10%. This is
largely due to the efforts of the Association of Rotational Molders (ARM), an international organization that includes molders, equipment suppliers, professional
consultants, and design rms, and the Society of Plastics Engineers (SPE), who
have recently formed a rotomolding division.
Initially only vinyl plastisols were used for rotational molding; however, in
the early 1960s, polyethylenes, the rst polyolen powders, were employed (1).
This created the opportunity for molders to enter markets where vinyl products
could not compete. In the early 1970s cross-linkable and modied polyethylenes
opened up more new areas, especially in the large-tank market. In the mid-1970s,
linear low density polyethylene, a major development in resins, was formulated.
In the 1980s nylon, polypropylene, and polycarbonate were introduced for rotational molding applications. The 1990s saw rotolining resins, materials that
bonded to metal, and one-step foam resin systems that provided for a nished
part with a rotomolded outer skin and a foam-lled core. The year 2000 ushered
in single-site catalyst resins, some known as metallocenes as well as numerous
compounders providing blends of resins for very specic end use requirements.
Most resin is used as a ground powder, ranging in particle size from 20 to 120 mesh
(125840 m). Liquids and small-diameter micropellets can also be rotomolded.
Rotational molding provides a more uniform wall thickness, for both single- and
double-wall construction, than other methods. Thick corners impart strength. Inserts, ribs, and undercuts are easily included (2,3).
The range of designs is limitless. The ARM organization has published a
design manual for rotational molding (4). This was the rst publication to address
the design guidelines required in the rotational molding industry. Since that time,
numerous books have been published on rotomolding (5).
Molds and tooling costs are lower than those of other processing methods,
since channels for cooling water and resistance to a clamping force are not required. Different articles and colors may be molded on the same machine and in
the same cycle. Quick mold changes are possible when several short production
runs are required. Large, hollow products are conveniently made by rotomolding.
The largest article molded to date is an 85-m3 tank. Trimming can be eliminated
since very little ash is produced. Rotomolded parts are comparatively stress-free.
Corner sections are thicker than with other processes, which increases strength.
Encyclopedia of Polymer Science and Technology. Copyright John Wiley & Sons, Inc. All rights reserved.

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Undercuts, intricate contours, molded-in inserts, and double-wall construction are

routinely included; wall thicknesses are uniform.

Process
In most rotomolding operations the molds or cavities are lled with a certain
amount of powder or liquid (charging the molds); the mold halves are pressed
together by bolts or clamps, placed in a heated oven, and rotated biaxially. During
heating the resin melts, fuses, and densies into the shape of the mold. The molds
are moved into a cooling chamber, where they are slowly cooled by air and water.
After removal from the cooling chamber, the molds are opened and the nished
articles are released.
Many rotomolded parts are produced in the color of the plastic. For colored
parts, suppliers provide a compounded colored resin; however, many molders blend
a dry color into the resinfor this operation, addition and dispersion are critical.
New developments in liquid colors allow for use at both the compounder and rotomolder. Nylon and polycarbonate may require drying before molding. Although
scrap or regrind is not produced in large quantities, only a small percentage of
regrind should be used with the virgin resin.
The particle size of the resin is extremely important; 500-m (35-mesh)
powder is the standard of the industry, although coarser or ner grinds may be
employed.
Wall distribution is determined by the rotation ratio. The fewer rpms in a certain ratio, the more uniform the wall thickness. Resin, molds, and nal application
must be taken into consideration to establish the most efcient cycle.
Equipment. The equipment used in rotational molding is simple; many
variations are available. The most common type is the so-called carousel type
(Fig. 1). This machine consists of a heating station or oven, a cooling station (frequently an enclosed chamber), and a loading and unloading station. A carousel has
three to six spindles or arms where the mold or molds are mounted. Most carousels
have the freedom to revolve in a complete circle. The spindles are mounted on a
central hub and driven by variable motor drives. New control systems allow each
arm to operate independently in movement and control of oven temperature and
time. Microprocessors are incorporated in the control system. Computer simulation software can be utilized in prototyping and manufacturing.
The ovens are usually red with natural gas and equipped with blowers to
distribute the heat throughout the chamber. Some ovens can be heated by oil or
propane gas, but natural gas is preferred. A new composite mold technology is also
available to produce rotomolded parts. This is done without an oven as heating
and cooling takes place inside the mold.
A fan provides forced air to the cooling station for the initial cooling, whereas
a water system cools the molds and products. A spray mist is used for even cooling.
The cooling station may or may not be enclosed.
In an open-ame machine a mold is rotated on a single axis over an open
ame. After the article is formed, the excess resin is discarded and the ame is
turned off to allow for air-cooling. This process requires a longer cycle time, but
the equipment is less expensive.

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Oven

Loadunload station
Cooling station

Molds

Fig. 1. Carousel-type machine.

The shuttle-type machine (Fig. 2) is used for large products, such as tanks.
A frame for holding a mold is mounted on a movable bed. The drive motors for
turning the mold biaxially are incorporated in the bed, which is on a track that
allows the mold and bed to move into and out of the oven. After the heating cycle
is completed, the mold is moved into the cooling station, which is not enclosed,
Another bed with a mold is moved into the oven from the opposite end. (Some
shuttle machines will use a movable oven.)
The clamshell type of rotational molder utilizes an enclosed area that serves
as both the oven and the cooling station (Fig. 3). This machine employs only one
arm; heating, cooling, and loadingunloading stations are all in the same location.
Rock and roll machines are commonly used for kayaks and canoes. These
machines do not rotate biaxially but will rock back and forth while spinning on

Door

Oven

Door

Station 1

Station 2

Mold

Mold

Cooling, loading, and unloading

Cooling, loading, and unloading

Fig. 2. Shuttle-type machine.