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Precision Rotational Molding

Precision rotational molding (PRM) is a highly effective manufacturing process used to create hollow plastic parts with uniform wall thicknesses and intricate geometries. The process involves heating a plastic resin material within a mold that rotates biaxially to ensure uniform distribution and formation of the required shape. This technique is ideal for producing large, complex components in low to medium production volumes.

Lerner Molded Plastics has been a leader in precision rotational molding for over 35 years, providing high-quality custom-molded solutions to the OEM, automotive, and consumer product sectors. Our extensive experience and state-of-the-art facilities allow us to handle projects of varying scales and complexities, with a focus on quality and customer satisfaction.

Precision Rotational Molding Process

The PRM process involves the following steps, each of which is crucial to achieving the final product’s specifications:

  • Material Loading. The process begins by placing a predetermined amount of plastic resin, typically in powder form, into the mold.
  • Heating and Rotation. The mold is then subjected to heat while rotating on two axes simultaneously. This dual rotation ensures the resin melts and evenly distributes across the mold’s internal surfaces.
  • Cooling. The mold cools as it continues to rotate, solidifying the plastic part. This controlled cooling process prevents warping and maintains the part’s dimensional accuracy.
  • Demolding. The finished plastic part is carefully removed from the mold once it has completely cooled and solidified.

Lerner Molded Plastics enhances this process by providing a range of secondary services, including in-line or post-molded assembly, machining, ultrasonic welding, decorating, barcoding, labeling, and complete supply chain and logistical support.

Benefits of Precision Rotational Molding

Precision rotational molding offers a range of advantages that make it a preferred choice for various applications:

  • Flexible Designs. PRM allows for the creation of complex shapes and intricate designs without joints or seams.
  • Cost-Effectiveness. Compared to other molding techniques, PRM typically involves lower tooling costs, making it a cost-effective choice for prototypes, short production runs, and custom projects.
  • Uniform Wall Thickness. Rotating the mold biaxially ensures the molded parts have a consistent wall thickness throughout. This uniformity improves the durability and structural integrity of the end product.
  • Minimal Material Waste. PRM is a material-efficient process that minimizes waste. Any excess material can often be recycled, contributing to sustainable manufacturing practices.

Precision Rotational Molding Applications

The versatility of PRM makes it suitable for a diverse range of applications across various industries:

  • Automotive and OEM Parts. PRM is used to manufacture parts such as fuel tanks, dashboards, and HVAC housings.
  • Consumer Goods. This process is employed in the production of items like furniture components, toys, and pet products.
  • Industrial Applications. PRM is ideal for creating durable products like water purification tanks, pressure transducer housings, and various types of storage containers.
  • Medical Equipment. Precision rotational molding can be used to produce medical devices and equipment, including medical cases, prosthetics, and waste containers.

Lerner Molded Plastics’ expert PRM capabilities have allowed us to successfully produce large water purification tanks and other types of complex components that align with customer requirements.

Precision Rotational Molding From Lerner Molded Plastics

With over 35 years of experience, Lerner Molded Plastics is a trusted provider of precision rotational molding solutions. Our dedication to quality, innovation, and customer satisfaction makes us the ideal partner for businesses seeking reliable and efficient plastic manufacturing services.

For more information about our PRM capabilities, or to discuss your project requirements with our expert team, request a quote today.