Rotomoulding presentation.pdf

Rotational Moulding –

Why & Who

Karen Drinkwater

Tel: 01386 791547

Fax: 01386793211

www.jscrotational.co.uk

[email protected]

http://www.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

Rotomoulding In the UK

The UK’s 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

Rotational Moulding is the dispersion of

finely divided powders by tumbling in a

rotating and heated closed mould.

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 bi-

axial manner.

Rotational Moulding

What Can Rotational Moulding

Produce?

European Rotomoulding Sectors

Hollow Items

Design freedom

Undercuts

Organic shapes,

complicated curves

Multi-featured

components with no

welding required

Variety of sizes up to

50,000litres

Design Highlights – Shape & Size

Value added

Design

Chemical Resistance

Hygienic:

• Cleanable

• Antibac Polymers

UV stable:

• Light Fastness

• Structural Integrity

Child safe

Food safe

Design Highlights – Material Properties

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

Shape

Corrugation

Ribs

Kiss-points

Moulded-in

strengtheners

Design Highlights – Enhancing Strength

Value added

Design

Moulded-In Features

Moulded-In inserts

Moulded threads

Can be matched/

complemented by

components produced

by other methods

Design Highlights – Base Component

Value added

Design

Any pantone

Material Effects:

• Mottles

• Wood

Opaque allowing

illumination

Design Highlights – Finish

Value added

Design

Design Highlights – The Big Green Issue

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

Reduce

Recover

Recycle

Re-use

The 4 R’s

John Barker

Technical Directorwww.cromptonmouldings.co.uk

Tel: 01484 401331

[email protected]

http://www.cromptonmouldings.co.uk/

mailto:[email protected]

To produce a high pressure vessel for the storage of hydrogen gas for

use in fuel cell vehicles

Case Study -

DURASTOR

CROMPTON MOULDINGS LTD

John Barker – Technical Director 6th June 2013

www.h2vessel.co.uk

http://www.h2vessel.co.uk/

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


-CAPACITY-

Two identical Alan Yorke HB 260 Carousel Machines

capable of providing mouldings up to 1m3


-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


Rotational Moulding of Vessel

Liners

http://www.innovateuk.org/

http://www.eplcompositesolutions.co.uk/


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

http://www.ctgltd.co.uk/

http://www.brookes.ac.uk/


Ticona Engineering

Polymers

Development and Supply of

Vessel Materials

Delta Motorsport Ltd

Development of Case Study

Design

http://www.delta-motorsport.com/

http://www.ticona.com/

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

http://www.h2vessel.co.uk/

http://www.cromptonmouldings.co.uk/

www.leafield-environmental.com

2011/Parking and Site Safety/www.leafield-environmental.com

Breaking Boundaries

In Rotational Moulding

Problem: Recycling in large operational environments

Quick release lift with

snap fit connections

High

specification

pivot out sack

frame sitting

into elongated

slot

Moulded in

metal

linkage

poles

Solution: Recycling pedal bin

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

Problem: Adapting an existing product at the NEC

10 bins per stack

40 bins per pallet

1

2

3

Just 3 pieces…

Solution: Simplicity & versatility

Mechanism damage

Labels cracking

Fabrication weakness

Problem: To create an easily serviceable, bounce back

bollard meeting regulatory standards

• No mechanical joint

• Resistance to HGV wheel drive over

• Min 70km/h high speed impact resistance

• Passively safe & return to upright

Solution: A bollard with bounce, exploiting the properties of

Reflex MDPE

• 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)

Reflex base section

with no mechanical

joint

Rigid upper section

to reduce label

cracking (high speed

standard impacts)

Reflex base with

replaceable rigid

top

Stuart Wright

Tel: 01636 611959 Fax: 01636 707369

www.rototek.com

[email protected]

http://www.rototek.com/


Technical rotational mouldings from concept to

manufacture

www.rototek.comSylvan Way, Old Great North Road, Balderton, Newark, Nottinghamshire. NG24 3UT

Tel: 01636 611959 Email: [email protected]

Case Study

Working with rotational moulders

to bring successful products to

market


manufacture



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

Over the years have won numerous design and industry awards

Involved in many market sectors with a portfolio of over 150 products ranging

from 1ltr tanks to 5m sailing dinghy hulls


manufacture



Background

2009

The Department of Health and

the Design Council challenged

the UK’s design and

manufacturing community to

design and prototype new

hospital furniture and

equipment that will help to

reduce Healthcare Associated

Infections (HCAIs).

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=lM8nkyl7gYYaoM&tbnid=t7f7wtKlRabadM:&ved=0CAUQjRw&url=http://www.nonon.co.uk/2009/09/design-bugs-out/&ei=HoisUfXGIsSh0QWX3YGYDg&bvm=bv.47244034,d.ZG4&psig=AFQjCNGWKAs1jfN1tk2174DWaGVE6bJF4g&ust=1370347926527600


manufacture



Background

“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.

“


manufacture



A supplier to the medical and care sector for over 60 years with a range

of more than 1500 products.

Partners

An award winning innovation and design consultancy. Expertise offered

encompasses user research, creative innovation, design development

and prototyping.


manufacture



Problem

Traditional furniture is has tight corners and crevices making it very difficult to

clean.

Handles, hinges, joints etc are awkward to get to!


manufacture



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


manufacture



Concept Generation


manufacture



Concept Generation


manufacture



Meet with manufacturing partners


manufacture



Meet with manufacturing partners

Considerations included:

• Loading of material

• Material flow

• Flat walls

• Strength

• Surface finish

• Corner radii

• Parting lines – position and quality


manufacture



Product Development


manufacture



Full scale prototypes


manufacture





manufacture





manufacture



Lockable top drawer -

electronic lock (no key

hole)

Top shelf

Open access middle shelf

with raised edges.

Shelf faces the patient

bedside.

Lower drawer

Wipe clean castors 100mm

Open easy clean handles

Open access base tray.

Easy to wipe over

continuous front surfaceRotationally moulded from

high density polyethylene

Chemical resistant and

No joints / junctions

Design Detail


manufacture



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


manufacture



Mould Trials


manufacture



Mould Trials


manufacture



Product launch

Launched April 2010


manufacture



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

Shaun Champion MCMI

Sales & Commercial Directortel: + 44 (0) 844 264-1-264fax: + 44 (0) 844 264-0-264www.corillaplastics.co.uk

[email protected]

ProjectAir intake filter housing for new V6

Roadster

http://www.corillaplastics.co.uk/

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?

Designing for Rotomoulding

USE OUR EXPERTISE

Taking it further………..

Designing for Rotomoulding

USE OUR EXPERTISE

Taking it further………..

Tel: +44(0) 20 7457 5013/ Fax: +44(0)20 7457 5045

Email: [email protected]

http://www.bpf.co.uk/Members/Rotational_Moulding_Group


http://www.bpf.co.uk/Members/Rotational_Moulding_Group

Documents

Rotomoulding presentation.pdf