Premier Plastics®

Molding

Plastic technology has advanced dramatically in the last few decades and it's obvious to see the increase in plastic products in our everyday lives. Before going into the details on the specific types of molding offered at Premier Plastics, it's important to see first the advantage of using plastic compared to durable metal products. The following lists how recent technological advances have increased the various benefits of plastic:

Rust Resistant
Plastic cannot rust. Even products made of stainless steel can rust in sensitive areas such as welded spots.

Chemical Resistant
Plastic can endure various chemicals, and can be engineered to be static, fire, and weather resistant.

Durable
Plastic parts are immensely impact proof and do not dent. Because of this, plastic products last much much longer than metal products.

THERMOFORMING

Thermoforming, more commonly called vacuum forming, is the manufacture of plastic components through a pressure forming process. Vacuum forming is performed by using a thermoplastic sheet (Refer to our Services page for a complete listing of specific plastic materials we use in vacuum forming). The sheet is heated to a flexible state and then placed over a mold and drawn into the mold to the desired shape of the finished part.

Just like roto-molding, vacuum forming is performed in steps, but that is where the similarities end. The first step in vacuum forming is creating a master pattern to produce the mold. The pattern and its framework are constructed to shape the outside of the mold. A variety of materials can be used to form the mold. Once the mold has set, it is then mounted on a back plate and vacuum holes are drilled through the mold and around the outside edge of each pattern. This allows the heated plastic sheet to be pulled completely over the mold to ensure a perfect part.

After all the preparations of the mold have been completed, the manufacturer is then ready to perform the actual vacuum forming process. The plastic sheet is placed over the mold and clamped into place. The plastic sheet is heated and a vacuum is applied from beneath the mold. The heated plastic is then drawn into the cavity. After the plastic has been allowed to cool, the clamps are taken off and the newly formed parts are taken from the mold. The final step is to then cut out the individual molded parts and remove any sharp edges or corners.

THE BENEFITS OF THERMOFORMING Vacuum forming is highly constructive and very cost-effective for the production of many plastic parts. Vacuum forming offers high tolerances, tight specifications, and sharp detailed parts.

For customers looking for an economical way to test new designs and product markets, vacuum forming is often the answer. This is because modifications to the design are often performed in an easy manner.

Recent engineering advancements in thermoplastic materials have greatly contributed to the production of parts and prototypes by vacuum forming techniques, giving Premier Plastics even more ways to produce a product just right for you.

THE ADVANTAGES OF THERMOFORMING Adjustments can be made when necessary in vacuum forming, giving it advantages over other types of molding. These advantages are as follows:

• Easy Modification
• Low Initial Project Costs
• Short Production Times
• Short Tooling Lead Times
• Effectively Penetrates Small Volume Markets

THERMOFORMED PRODUCTS Vacuum formed products are becoming increasingly popular because of the low cost and convenient modification. Customized instrument panels, tables, trays, tractor roofs, and sinks are only a very small idea of products that are thermoformed. New products are being created in thermoforming everyday. Please refer to our Products page to see some of the products we actually manufacture, or go to our Contact Us page with any new ideas and find out what we can do for you!

ROTATIONAL MOLDING

Rotational molding, or more commonly called roto-molding, is an economical way to produce large parts. Different types of plastic such as polyethylene, PVC, nylon, and polypropylene, are broken down into a usable resin (Refer to our Services page for a complete listing of specific plastic materials we use in roto-molding). This plastic resin is then loaded into a mold that is combination heated and rotated in a slow, yet constant motion. This simultaneous process of heating and rotation distributes the material on the inner surfaces of the mold and combines it together.

Roto-molding is a four-step process, made up of Loading, Heating, Cooling, and Unloading the mold. In the Loading stage the pre-measured plastic resin is loaded into the mold. The filled molds are then closed and moved into the oven, where they slowly rotate on two axes. As the heat penetrates into the molds, the melting resin adheres to the mold's inner surface until it is thoroughly fused, evenly coating the entire surface.

During the Cooling stage, the mold continues to be rotated to maintain even walls as a high velocity air current gradually cools the mold. The mold is then opened, the finished part removed, and the mold is ready for its next step.

Unlike other plastic molding processes, roto-molding produces seamless parts with consistent wall thickness and more material in corners. This is in order to absorb shocks and stresses where they are most likely to occur.

Roto-molding offers outstanding flexibility and precision. Complex contours such as metal inserts and flanges can be made right into the walls requiring fewer steps to produce your finished product. In addition, roto-molded plastic eliminates sharp corners and burrs and results in a smooth and seamless product. This reduces the risk of injury for operators.

A wide spectrum of colors are available with roto-molding. There is also no chipping because the color is solid throughout the whole part.

Roto-molding offers many distinct advantages over other types of molding such as blow molding or injection molding. The advantages are:

• Dramatic Cost Savings
• Short Production Times
• Easy Modification
• Superior Strength
• Ability to Produce Multi-Wall Moldings

Rotational molding is incredibly versatile and is able to handle a vast variety of shapes and sizes. Toys, play houses, drain tile fittings, automotive parts, kayaks, fuel tanks, and park equipment are only a few of the numerous products that can be made. As you can see in the above list, the products produced are only limited to the imagination.

Although the possibilities for roto-molding are endless, the thermoforming method of molding may be what you need. Read on to find out more!

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Premier Plastics is very innovative in offering two kinds of molding: Thermoforming and Rotational Molding. Click the tabs below to find out which type will work best for you!