Download - Rotomoulding presentation.pdf
Rotational Moulding –
Why & Who
Karen Drinkwater
Tel: 01386 791547
Fax: 01386793211
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
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
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
Ticona Engineering
Polymers
Development and Supply of
Vessel Materials
Delta Motorsport Ltd
Development of Case Study
Design
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
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
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
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]
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
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]
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).
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]
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.
“
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]
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.
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]
Problem
Traditional furniture is has tight corners and crevices making it very difficult to
clean.
Handles, hinges, joints etc are awkward to get to!
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]
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
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]
Concept Generation
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]
Concept Generation
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]
Meet with manufacturing partners
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]
Meet with manufacturing partners
Considerations included:
• Loading of material
• Material flow
• Flat walls
• Strength
• Surface finish
• Corner radii
• Parting lines – position and quality
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]
Product Development
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]
Full scale prototypes
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]
Full scale prototypes
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]
Full scale prototypes
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]
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
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]
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
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]
Mould Trials
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]
Mould Trials
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]
Product launch
Launched April 2010
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]
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
ProjectAir 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
Project Time Line Continued
8. Cast bottom part of tool (LM25)
9. CNC top part of tool
10. Finish tool (spilt line / clamps / frame)
Project Time Line Continued
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