Rotomoulding Presentation PDF

Rotational Moulding Why & Who
Karen Drinkwater
Tel: 01386 791547 Fax: 01386793211 www.jscrotational.co.uk Karen.drinkwater@jscrotational.co.uk
The BPF Moulders Group was founded in 1978 and represents and promotes the interests of all those involved in the rotational moulding process in the UK. The Rotational Moulding Group works to secure a wider appreciation of the potential for rotational moulding
The UKs rotational moulding industry is one of the strongest in the EU. It consists of: 70 moulding companies 90 firms providing key services to the sector, ranging from raw materials to design services. Employing 1500
Rotomoulding In the UK
Rotational Moulding is the dispersion of finely divided powders by tumbling in a rotating and heated closed mould.
Rotational Moulding
Rotational moulding is unique. No external pressure is applied during forming. The process consists of several stages: Loading of polymer Heating Cooling De-moulding During heating/cooling the moulds are continuously rotated in a biaxial manner.
What Can Rotational Moulding Produce?
European Rotomoulding Sectors
Hollow Items
Design Highlights Shape & Size
Undercuts
Organic shapes, complicated curves Multi-featured components with no welding required Variety of sizes up to 50,000litres
Design freedom
Design Highlights Material Properties Chemical Resistance Hygienic: Cleanable Antibac Polymers UV stable: Light Fastness Structural Integrity Child safe Food safe
Value added Design
Design Highlights Material Properties

Polyethylene Nylon Cross Linked PE Polycarbonate Clarity, Rigidity PVC Paintable, Flexible Additives Flame Retardancy Antibacterial Foam
Value added Design
Design Highlights Enhancing Strength
Shape
Corrugation Ribs Kiss-points Moulded-in strengtheners
Value added Design
Design Highlights Base Component
Moulded-In Features
Moulded-In inserts
Moulded threads
Can be matched/ complemented by components produced by other methods
Value added Design
Design Highlights Finish
Any pantone Material Effects: Mottles Wood Opaque allowing illumination
Value added Design
Design Highlights The Big Green Issue
The 4 Rs
Reduce Re-use
Good design significantly minimises material Highly durable products Products can be recycled And/or made from recycled polymer Energy can be recovered:- High Calorific Value
Recycle Recover
Value added Design
John Barker Technical Director

www.cromptonmouldings.co.uk Tel: 01484 401331 john.barker@cromptonmouldings.co.uk
CROMPTON MOULDINGS LTD
Case Study DURASTOR

To produce a high pressure vessel for the storage of hydrogen gas for use in fuel cell vehicles
www.h2vessel.co.uk
John Barker Technical Director
6th June 2013
Crompton Mouldings Ltd -BACKGROUND Formed January 2007 Part of Crompton family of Companies including: Crompton Controls Ltd - Wakefield Turnell & Odell Ltd - Northampton Building on five years business development in custom mouldings
Crompton Mouldings Ltd -CAPACITY-
Two identical Alan Yorke HB 260 Carousel Machines capable of providing mouldings up to 1m3
Crompton Mouldings Ltd -EXAMPLES Environmental products Construction products Gardening and Leisure industry Water tanks Medical products Enclosures for electrical products Learning aids for use in Schools
DURASTOR What is it?

The Durastor hydrogen storage vessel is comprised of a rotationally moulded plastic liner and composite overwrap. Using the same thermoplastic material for both liner and overwrap results in a monolithic structure - the liner and reinforcement effectively become one.
DURASTOR Challenges
To have a design pressure of 700 bar. To have a burst pressure of at least 1400 bar. An operating life of at least 11,250 cycles. Permeation through the vessel must be less than 2.8 cubic cm per hour. Potential for vessel to be recycled at end of life. The need to create a suitable seal between boss, fitting and liner. Develop a way to consolidate the liner and reinforcement to improve strength & durability.
DURASTOR Consortium
DURASTOR is part funded by TECHNOLOGY STRATEGY BOARD
EPL Composite Solutions Consolidation of Vessel Structures and Overall Project Management
Crompton Mouldings Ltd Rotational Moulding of Vessel Liners
DURASTOR Consortium
Filament Winding of Vessel Reinforcement CTG Ltd Testing of Vessel Materials and Prototypes Element - Hitchin Ltd
Stress Analysis, Life Cycle Analysis and Recycling Opportunities Oxford Brookes University
DURASTOR Consortium
Delta Motorsport Ltd Development of Case Study Design
Ticona Engineering Polymers Development and Supply of Vessel Materials
DURASTOR Liner
DURASTOR Liner
Mould
DURASTOR Liner
Mould
DURASTOR Liner
Mould
DURASTOR Liner
DURASTOR Reinforced Liner
Thank you for your attention.

FOR FURTHER INFORMATION VISIT:www.h2vessel.co.uk www.cromptonmouldings.co.uk
www.leafield-environmental.com
Breaking Boundaries In Rotational Moulding
Problem: Recycling in large operational environments
Solution: Recycling pedal bin

Quick release lift with snap fit connections
Moulded in metal linkage poles
High specification pivot out sack frame sitting into elongated slot
Problem: Adapting an existing product at the NEC
Solution: Met and discussed clients exact needs Timescale was tight to meet exhibition season Product: Aesthetically pleasing Robust & nestable Logistically sound (out/in of exhibition hall in 30 minutes) Been in operation for 2 years
Solution: Simplicity & versatility

Just 3 pieces
2 3
10 bins per stack 40 bins per pallet
Problem: To create an easily serviceable, bounce back bollard meeting regulatory standards
Mechanism damage
Fabrication weakness
Labels cracking
Solution: A bollard with bounce, exploiting the properties of Reflex MDPE

No mechanical joint Resistance to HGV wheel drive over Min 70km/h high speed impact resistance Passively safe & return to upright
One piece flexible base
No creasing Rigid top to protect labels
Bends/folds in all directions
Two Products:
(Patent applied for moulding process 2 patents)
Rigid upper section to reduce label cracking (high speed standard impacts)
Reflex base with replaceable rigid top
Reflex base section with no mechanical joint
Stuart Wright
Tel: 01636 611959 Fax: 01636 707369 www.rototek.com stuart@rototek.com
Technical rotational mouldings from concept to manufacture
Case Study
Working with rotational moulders to bring successful products to market
Sylvan Way, Old Great North Road, Balderton, Newark, Nottinghamshire. NG24 3UT Tel: 01636 611959 Email: enquiries@rototek.com
www.rototek.com
Background
Rototek was formed in 1993 with a custom- built state of the art rotational moulding machine surpassing many that were available commercially. Has established a strong reputation as a technical rotational moulder Involved in many market sectors with a portfolio of over 150 products ranging from 1ltr tanks to 5m sailing dinghy hulls
Over the years have won numerous design and industry awards
www.rototek.com
Background
2009 The Department of Health and the Design Council challenged the UKs design and manufacturing community to design and prototype new hospital furniture and equipment that will help to reduce Healthcare Associated Infections (HCAIs).
www.rototek.com
Background
www.rototek.com
If hospital equipment and furniture is designed to be easy to clean and easy to use, it will stay cleaner and therefore help reduce the risk of infection.
Partners
A supplier to the medical and care sector for over 60 years with a range of more than 1500 products.
An award winning innovation and design consultancy. Expertise offered encompasses user research, creative innovation, design development and prototyping.
www.rototek.com
Problem
Traditional furniture is has tight corners and crevices making it very difficult to clean. Handles, hinges, joints etc are awkward to get to!
www.rototek.com
A solution?
Rotational moulding would lend itself very well to a solution as parts can be made with rounded corners Components can be made with handles and features moulded in
www.rototek.com
Concept Generation
www.rototek.com
Concept Generation
www.rototek.com
Meet with manufacturing partners
www.rototek.com
Meet with manufacturing partners

Considerations included: Loading of material
Material flow
Flat walls Strength Surface finish Corner radii Parting lines position and quality
www.rototek.com
Product Development
www.rototek.com
Full scale prototypes
www.rototek.com
www.rototek.com
www.rototek.com
Design Detail
Top shelf Easy to wipe over continuous front surface Lockable top drawer electronic lock (no key hole) Rotationally moulded from high density polyethylene Chemical resistant and No joints / junctions
Lower drawer Open access middle shelf with raised edges. Shelf faces the patient bedside.
Open easy clean handles
Wipe clean castors 100mm
Open access base tray.
www.rototek.com
Mould manufacture
A tool supplier was required to deliver tooling of the highest standard possible: Key requirements were: High gloss finish Seam free parting lines
Durability
www.rototek.com
Mould Trials
www.rototek.com
Mould Trials
www.rototek.com
Product launch
Launched April 2010
www.rototek.com
Summary
Key points to take from the case study: Manufacturers were consulted at the earliest possible opportunity
Suggestions from manufacturers taken on board and incorporated into the design
The design was sympathetic to the process and used the strengths to the best effect The rotomoulder was able to use their experience when specifying a mould manufacturer Both the client and the rotomoulder were able to work with the toolmakers to achieve the best quality mould
www.rototek.com
Shaun Champion MCMI Sales & Commercial Director

tel: + 44 (0) 844 264-1-264 fax: + 44 (0) 844 264-0-264 www.corillaplastics.co.uk shaun.champion@corillaplastics.co.uk
Project
Air intake filter housing for new V6 Roadster
Starting Point Time (6 weeks until samples required)

6
SLA Model of part
Must fit with an existing Ford part (Mustang engine)

Annual volume of only 500-600 parts Weight needs to be kept to a minimum Hostile working environment
Options considered Injection moulding (cost, time and volumes) Vacuum forming (deep draw, inconsistent wall sections) Rotational Moulding (Perfect)
Why rotational moulding? Lead-time Low cost tooling Thin wall section with strong corners Small to medium batch quantities Parts can be recycled (Automotive industry)
Project Time Line
1. Select a toolmaker (availability / quality / price) 2. Quote customer 3. Critical design points (Modified SLA model for RM process) 4. Receive the order 5. Produce a CNC model (From modified CAD file)
Project Time Line Continued
6. Review model with customer 7. Produce a pattern (base part of tool glass cloth and gel coat)
+1% pattern, +3% moulding
8. Cast bottom part of tool (LM25) 9. CNC top part of tool 10. Finish tool (spilt line / clamps / frame)
11. First off sample / check
First batch of 50 parts supplied
Summary Order to first off sample less than 6 weeks Tooling less than 7k Unit price (subject to batch size) Less than 25 Automotive application (fitting mating parts / hostile environment) Parts can be recycled (or manufactured from recycled material)
The right solution
Any Questions?
Taking it further..
USE OUR EXPERTISE
Designing for Rotomoulding
Taking it further..
USE OUR EXPERTISE
Tel: +44(0) 20 7457 5013/ Fax: +44(0)20 7457 5045 Email: jbloom@bpf.co.uk http://www.bpf.co.uk/Members/Rotational_Moulding_Group
Designing for Rotomoulding

Rotomoulding Presentation PDF

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Rotational Moulding Why & Who

Tel: 01386 791547 Fax: 01386793211 www.jscrotational.co.uk Karen.drinkwater@jscrotational.co.uk

What Can Rotational Moulding Produce?

European Rotomoulding Sectors

Design Highlights Shape & Size

Value added Design

Design Highlights Material Properties

Value added Design

Design Highlights Enhancing Strength

Value added Design

Design Highlights Base Component

Can be matched/ complemented by components produced by other methods

Value added Design

Design Highlights Finish

Any pantone Material Effects: Mottles Wood Opaque allowing illumination

Value added Design

Design Highlights The Big Green Issue

Value added Design

John Barker Technical Director

CROMPTON MOULDINGS LTD

Case Study DURASTOR

John Barker Technical Director

6th June 2013

Crompton Mouldings Ltd -CAPACITY-

DURASTOR What is it?

Crompton Mouldings Ltd Rotational Moulding of Vessel Liners

Delta Motorsport Ltd Development of Case Study Design

Ticona Engineering Polymers Development and Supply of Vessel Materials

DURASTOR Reinforced Liner

Thank you for your attention.

Breaking Boundaries In Rotational Moulding

Problem: Recycling in large operational environments

Solution: Recycling pedal bin

Moulded in metal linkage poles

Problem: Adapting an existing product at the NEC

Solution: Simplicity & versatility

Solution: A bollard with bounce, exploiting the properties of Reflex MDPE

No creasing Rigid top to protect labels

Bends/folds in all directions

Reflex base with replaceable rigid top

Reflex base section with no mechanical joint

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Meet with manufacturing partners

Technical rotational mouldings from concept to manufacture

Meet with manufacturing partners

Technical rotational mouldings from concept to manufacture

Technical rotational mouldings from concept to manufacture

Full scale prototypes

Technical rotational mouldings from concept to manufacture

Full scale prototypes

Technical rotational mouldings from concept to manufacture

Full scale prototypes

Technical rotational mouldings from concept to manufacture