Visual Encyclopedia of Chemical Engineering

Rotational Molding
Rotational molding is an economical way to produce hollow parts of all sizes.

(Copyright STP Rotomachinery, Cerano, Italy)

Process Map

General Information

In rotational molding, powder or liquid polymer is loaded into an empty mold. The mold
closes and enters a furnace where it is heated, melting the polymer. The mold rotates on
two perpendicular axes to ensure that the mold is evenly coated by the polymer. The
mold continues to rotate during cooling outside the furnace to maintain constant wall
thickness. After cooling, the mold opens and the part is removed.
Equipment Design

In fixed-arm rotational molding machines, such as the ones shown below there are typi-
cally three arms connected to a center turret. When the turret rotates, all the arms move
to the next station. In the case of long cooling times a fourth arm and a pre-cooling sta-
tion are added between the oven and cooler.

(Copyright STP Rotomachinery, Cerano, Italy)

A second type of rotational molder is an independent-arm machine. These machines have

up to four arms and five stations. Since each arm moves independently of the others,
heating and cooling times need not be the same. This flexibility results in increased effi-
ciency and higher quality parts.

Other types of rotational molders include the carousel and rock&rolling oven machines
shown below. The carousel molder shown on the left is used for the production of very
large volume items such as kayaks. These molders can be equipped with 3-4 arms that all
share the same oven and cooler resulting in reduced production times. The rock & rolling
oven, also known as the rocking oven, is shown on the right. The rocking oven typically
has a mold that is surrounded by an oven and heated by hot air. The design concept of
the rock & rolling oven machine is that it will have a rocking action about one axis, giv-
ing the "rock" aspect to its name, but it will also feature a "roll" where the oven will
rotate a full 360 o around the perpendicular axis.
(Copyright STP Rotomachinery, Cerano, Italy)

Usage Examples

Rotational molding is used in the automotive, toy, lawn and garden, watersport, and
industrial container industries to make anything from a small child's toy to a 6,000 gal-
lon tank. One interesting use of rotational molding is the manufacturing of medical
spineboards. After rotational molding, the medical spineboards are injected with poly-
foam that dramatically increase their structural integrity. Common materials used in the
process are polyethylene, polypropylene, PVC, and nylon.
(Copyright Sterling Tech., Lake City, PA)

(Copyright R&R Tech, Edinburgh, IN)

Advantages

Disadvantages

• Results in parts with constant wall thickness.

• Results in parts with strong, stress-free outside corners.
• Complex hollow or foam filled parts possible.
• Molds are inexpensive compared to injection and blow molding because they do
not need to withstand high pressure.
• Metal parts may be molded directly to plastic, eliminating additional assembly.

• Can't yield large production volumes as quickly as extrusion and injection blow
molding.

Acknowledgements
R&R Tech , Edinburgh, IN

Sterling Tech. , Lake City, PA

STP Rotomachinery , Cerano, Italy

References
Leaversuch, Robert D. "Process Gains Cited For Rotomold Unit With IR Heat, Tumbling
Oven." Modern Plastics March 1993: 28-9.

Leaversuch, Robert D. "Rotomolding Developments Are Keyed To Extending Process

Capabilities." Modern Plastics July 1993: 46.

Rosen, Stephen L. Fundamental Principles of Polymeric Materials . New York: John Wiley
& Sons, 1982.

Crawford, R.J., and James L. Throne. Rotational Molding Technology . Norwich, NY: Plas-
tics Design Library/William Andrew Pub., 2002

Developers
Amber Ratliff

Joseph Palazzolo

Henry Chen

Jackie Priestley