Rotomolding process PDF

p. 330.322.8707 e. gstout@blue-reed.com
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Gregory Stout
Rotational Molding Design
Blue-Reed, LLC
Part Design and
Tooling for
Rotational Molding:
How to Achieve Success in Every Project
Gregory Stout
Blue-Reed, LLC
4191 Courtiff Circle
Stow, Ohio 44224
www.blue-reed.com

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Introduction
• Greg Stout - designer specializing in
hollow plastic parts.
• Over (17) years experience with
rotational molding process.
• SolidWorks
• This presentation will illustrate how part
design and tooling design influence and
affect each other.

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Tooling and Part Design
• All design has limitations to obey or
follow.
• Material limitations.
• Mold or Tooling limitations
• Machine or Oven limitations.
• To achieve success in your designs
you must understand and know your
options.

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Tooling Options
• Cast Aluminum molds.
• Fabricated Aluminum or Steel
molds.
• CNC molds.

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Tooling Advantages
• Cast Aluminum molds:
1. Can Mold Very Complex shapes
2. Can use Pattern or Model as a design check
before pouring metal.
• Fabricated Aluminum or Steel molds:
1. Can Mold Nearly as Complex shapes
2. Can be lower cost.
3. Requires no Pattern or Model
4. Thinner mold wall makes for faster heat transfer.
5. Extremely large molds can be made
• CNC molds:
1. Very close dimensional tolerances can be held.
2. Requires no Pattern or Model
3. No Porosity

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Part Design
• The following are examples of how the mold
design was manipulated to help make the parts
be manufactured successfully.

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Dog Waste Receptacle & Bag Dispenser
• Two parts from two molds that
hinge together to form one part.
The top lid is a dispenser and the
bottom is a receptacle.

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• An inside look shows how diverse the parts are. The bottom
has no restrictions to shrink while the top has to shrink around
a large core.

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Features:
• Two large core pins.
• One small core pin.
• Large graphic area.
• Routered hole for bag insertion.
• Routered holes for bag dispensing.
• Pull pins for hinges.

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• Core is very deep in cavity to accommodate pull pins on
the side of the part and for the head of the router for the
hole to insert the boxes of bags.
• Notice the crown in the graphic area to fight warp.

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Features:
• Large graphic area
• Drilled holes for hinge to
match molded in holes
for lid.
• Recess in center for
mounting post
• Drilled drain holes in bottom.

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Problem:
The lid has restricted shrinkage and the bottom
has no restrictions on shrinkage. How will the
parts mate together if they don’t shrink the
same?
Solution:
Since the top will not shrink as much as the
bottom part, ¼” was taken out of the width of the
bottom and 1/8” was taken out of the depth of the
bottom part.

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Pontoon Bass Boat
• A Boat that was
originally vacuum
formed in two pieces
and then glued together.
Now molded as one
piece and foam filled.

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Pontoon Bass Boat
• Boat has to be strong and solid in feel when stood on.
• Walls have to withstand clamping force of motor mount and
forces when motor is running.

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Pontoon Bass Boat
• Foam filling has to happen in mold and no holes can be left
open.
• Areas in the mold have to be close enough to form a kiss-off
and yet open enough to let both materials flow.

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Pontoon Bass Boat
• Drop Boxes were used for foaming the part in mold.
• Study was done to find out the optimal kiss-off, foaming
distance.
• Holes from the Drop Boxes were filled with an additional
storage feature for the part.

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29 Gal. Gas Walker
• Many threaded features
• Had to pass DOT Packaging Certification tests
• Needed to have consumer appeal.

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29 Gal. Gas Walker
• Many molded in graphics as well as post molded
graphics
• Many ribs for strength also add problems with porosity
at P/L for mold maker.

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29 Gal. Gas Walker
• Large center core difficult for mold
maker to pour.
• Part had to be stackable for
shipment and for testing.
• DOT Testing spec.: Part had to
withstand 1100 lbs. stacking force
for 28 days with no deformation.
• DOT Testing spec.: Hydrostatic
Pressure of 17.5 PSI for 30 min.
with no deformation.
• Part had to have no more than
.200” wall thickness.

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29 Gal. Gas Walker
• Ribs to prevent
distortion from tests.
• Must hold at least the
amount on label.
• Limited room for
threaded caps and
bushings
• Be careful of narrow
walls for finishing and
texturing.

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29 Gal. Gas Walker
• Pull pins for axle
pins through two
walls on each side
for strength.
• Molded in insert for
hose valve is a tight
area for machining in
the mold

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Sharbade Scooter
• Game scooter for children, adults and for the
physically disabled.
• Has to support 250 lb. athlete.
• Has to approximate design of current foam
covered plywood scooter.

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Sharbade Scooter
• Part had to be deep enough to allow resin
powder movement and to charge it in one mold
half. 3:1 is standard but can go lower.
• Needed to run FEA to determine amount and
style of slots.

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Sharbade Scooter
• FEA results were very good in both stress and
deformation. Hint: Red – bad; Blue – good!
• The plastic part could actually hold 440 lbs. easily.
• Warning: FEA is a design guide. Actual behavior of product
could be different. Too many processing variables.

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Sharbade Scooter
• Slots or holes give you the most added strength.
• If the part were larger, wider slots would give more room for an
opening in the flange in the tool to help with air flow.

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Sharbade Scooter
• Mounting posts in the slots make for better shut-off, no flash.
• Don’t make slots so narrow that the tool will be solid resulting
in a cold spot which will make for a thin wall.

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Sharbade Scooter
• Registration in the slot bosses to keep mismatch of P/L to a
minimum.
• Vent hole will be covered up on the finished part by the caster
mounting plate.
• Quick-Sert pins to hold the molded in inserts for the casters.

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Tank/Skid
• Customer needs large tank in certain
sized footprint.
• Must be able to move with a hand
truck or a tow motor.
• Oh, no! Two sizes are needed!

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Tank/Skid
• Larger size- no problem. Use an
additional mold piece to enlarge the
tank portion of the mold.
• Whaddaya mean it’s got to fit in the
oven!??

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Tank/Skid Oven Fit
• Modeled the molders oven
• Expanded the part to include part shrink
• Modeled the P/L flange, mounting posts and spider tubing.
• Insert model assembly into the oven and look for conflicts with
oven limits and the part- remember mold wall thickness

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Tank/Skid Oven Fit
• Areas that had to be adjusted were the hose hanger
at the top right had to move in and the threaded cap
needed to move closer to the center- a clamp has to
hold it in.

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Tank/Skid
• Mold with insert for larger size
tank capacity.
• Fabricated aluminum mold.

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Typical Fab Mold
• Square mounting posts that are
welded on.
• Flat P/L with dowel pin registration.

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• Clamping Parting lines in different planes.
Multi-Piece Fab Mold

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• Another view
Multi-Piece Fab Mold

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• Round parts are best parted through the
cross section rather than down the length
to ensure roundness. The lengthwise
parting line will make the part come out
oval shaped instead of round.
Fab Mold

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• Large sheet metal mold.
Fab Mold

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• Some parts of a Fab mold may be machined.
Fab Mold

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• Fabricated mold with kiss-offs.
Fab Mold

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• Multiple piece Fabricated mold.
Fab Mold

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• Fab molds are repeatable.
Fab Mold

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Fab Mold
• Fabricated molds can be very large and of
complex shapes.

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• Computer generated 3D models are used
by some fabricated mold makers to make
the sheet metal pieces.
Fab Mold

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• Large fabricated mold with complex
geometry.
Fab Mold

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• The backside of the same mold.
Fab Mold

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• Bending the sheet metal for the fab mold.
Fab Mold

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• A Sheet Metal tube mold.
Fab Mold

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• Sheet Metal tube mold spot welded.
Fab Mold

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• More complex shapes from
a fab mold.
Fab Mold

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• Large pull pins to create holes in the part in
a fabricated mold.
Fab Mold

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• Clamping directly through the parting line
flange on a fabricated mold.
Fab Mold

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• Fine polish of a sheet metal mold.
Fab Mold

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• Complex parting line in a fabricated mold.
Fab Mold

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• Molded in arrow logo in a fabricated mold.
Fab Mold

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• Kiss-offs and other complex geometry.
Fab Mold

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• Duplicates of fabricated molds.
Fab Mold

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• Another very large fabricated mold. Too
large to be cast in one piece.
Fab Mold

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• Nice crisp lines.
Fab Mold

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• Spider tubing bent instead of pieced welded
together. Very clean and strong.
Fab Mold

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• Clamping directly through a very complex
parting line.
Fab Mold

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Fab Mold
• Large cone shaped mold.

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6 Gal. Fuel Tank – Cast Mold
• A three piece cast mold with
one male thread and two
female threads molded in.
Room must be left for the pins
and bushings.

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Cabinet – Cast Mold
• Cast mold with
multiple pieces on
slides and hinges,
with pull pins and
molded in inserts.

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Spider Height Issues
• Die spring within mounting post. A way
to reduce the overall spider height.

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Spot Teflon Coating
• Spot Teflon coating allows
areas with deep cores to be
pulled easier.

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Cast Mold
• Multiple piece cast mold.

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• Multiple piece cast mold. Notice the
heavy duty slide for the mold piece on
the right.
Cast Mold

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• Completely removable mold piece.
Cast Mold

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• The other side.
Cast Mold

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• Close up of slide for large mold piece.
Cast Mold

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• Mold opened on slide.
Cast Mold

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• Another view of the slide.
Cast Mold

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• The inside of the cast mold with Brown
Teflon coating.
Cast Mold

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• Another view.
Cast Mold

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• Kiss-Offs for strength.
• Difficult for the foundry.
Cast Mold

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• Multiple piece mold on
slides and hinges enable
molding of what would
have been undercut. Nice
mold detail to the right.
Cast Mold

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• A precision slide for a molded undercut.
Cast Mold

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• Close up of slide.
Cast Mold

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Various Clamps

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Pneumatic Clamp
• Normally used on multiple cavity spiders
to clamp and unclamp quickly.

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• Heat pins or fins attracts more heat
to a particular mold area which will
thicken the part wall in that area.
Cast Mold

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• Heat pins can be put all over.
Cast Mold

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• More heat pins! To help reduce cycle time.
Cast Mold

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• Heat pins used to help heat a deep core
that would be difficult to get hot oven air to.
Cast Mold

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• This is a wooden pattern or model -
critical to making the cast mold. The
model has both plastic material shrink
and aluminum shrink factored in so it is
actually larger than what the part will be.
Cast Mold
• The model is
often used to
communicate
parting line and
other info.

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• Foundry tooling to make the sands
that the metal is poured into.
Cast Mold

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• Pouring molten aluminum into the sand
castings.
Cast Mold

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• Mold polishing. Necessary in all mold
making.
Cast Mold

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• Another multiple piece mold.
Cast Mold

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• Close up of a kiss-off in a
cast mold.
• Usually a good idea to
leave metal safe in the
mold to allow the molder
to adjust.
Cast Mold

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• A cast mold with an insulated
area on top. This will make
the insulated area mold a
large open area.
Cast Mold

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Mounting Plate
• A mounting plate.

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Grate
• This is a grate for mounting
numerous dissimilar molds.

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Grate Mount
• Two molds mounted on a grate.

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Multiple Mold Spider
• Multiple molds on a spider to make more
parts in the same amount of time.

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Air Amplifiers
• Air Amplifiers direct the heated air to a
particular area that may be difficult to heat
or to make a particular area’s wall thickness
thicker.

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Pull Pins
• Pull pins are used to create molded in
holes in parts.

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European Mold Making
• The following are examples of how the European
mold makers are making strides in our industry.

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Cast Molds
• A large complex cast mold with a lot of different mold
pieces to produce a lot of different configurations.

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CNC Molds
• CNC molds
make up
approximately
40% of the
molds sold
there.

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CNC Molds
• Nice multiple piece CNC mold.

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CNC Molds
• Another good example.

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CNC Molds
• A CNC mold for a liquid nylon
part.

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CNC Molds
• Another complex mold!

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Model, Mold, and Part Inspection
Complete Moulds
CTR Dimensional
control, to ensure
Tolerances,
Shrinkage and
correct Shape.
• Available with
some mold
makers in the
USA.

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Machines
• The next slides will talk about advancement in
automation for the rotomolding machines.

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Leonardo Machine
• A fully automated
rotomolding
machine – no
operator!
• When will we see
them in the US –
Very soon!
• See the
presentation later
today!

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• Human resource reduced to machine set-
up, human influence eliminated from the
product quality.
• Improved product quality thanks by the
uniform wall thickness distribution.
• Increased productivity.
• Absence of mould refurbishment needed.
• Clean and fresh working area.
Leonardo Machine

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• Automatic mould opening/closing.
• Automatic moulds control: product
demolding, inserts loading, material
loading, mould temperature control.
• Alarm signals in case of danger or
Dysfunctions.
• Automatic product demolding.
• Accurate Material dosing system.
Leonardo Machine

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Rotomolding process PDF

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Rotomolding process PDF