design for manufacturing - class 7 part 1 - rotomolding
Post on 13-Jul-2015
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DRAGON INNOVATION, INC. !
DESIGN FOR MANUFACTURING !
COURSE 7: PART 1 - ROTOMOLDING !!!!!!!
SCOTT N. MILLER | CEO | @DRAGONINNOVATE | WWW.DRAGONINNOVATION.COM
•Overview •Process •Part Design •Materials
AGENDA
Rotomolding Overview
Typical Rotomolded Parts
• Hollow Parts
• Storage Containers and Vessels
• Doll Heads and Limbs
• Kayaks and Outhouses
Rotomolding Advantages
• Hollow parts in one piece with no weld lines • Suitable for large parts • No internal stresses due to flow • Undercuts are OK • Suitable for short and high volume. • Can use multiple colors. • Shorter and cheaper tooling times (non pressurized). No
purging required between shots. • Minimal scrap (no “plumbing”) • Outside corners are stronger than blow molding • Can use rigid or flexible materials
Rotomolding Disadvantages
• Larger parts have a slow cycle times due to cooling time constants.
• Some geometrical features (such as ribs) can difficult to mold.
• Can’t control wall thickness precisely • Material cost will be higher due to additional processing
required
Rotomolding Process
Rotomolding Process
1. Fill Mold with metered shot. 2. Heat & Spin. Resin adheres
to inside surface of mold. Spinning results in relatively even wall thickness.
3. Cool 4. Extract
http://en.wikipedia.org/wiki/Rotational_molding
Rotomolding Machines
Example: Kayak Fabrication
Example: Baby Doll
Rotomolding Part Design
Design Guidelines
• Hollow part with ~ uniform wall thickness • Can include inserts and undercuts • Tune wall thickness by varying shot weight (0.8mm -
25mm) • Avoid nooks and crannies / ribs • Typically uniform wall, but can use stop process to thicken
one side
Materials
Common Materials - Polys
Material Young’s (MN/m2)
Yield (MN/m2)
Spc Gravity (g/cm3)
Cost ($/kg)
Melting Temp (C)
PE (85%) 70,000 250 6.6 1.80 420
PP 80,000 330 5.8 1.90 430
PC 28,000 70 1.13 4.00 130
PVC 45,000 150 1.8 2.93 650
Nylon 100,000 215 8.4 6.60 950
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