The Complete Guide To Plastic Rotational Molding

A GUIDE TO
PLASTIC ROTATIONAL MOLDING

IN THIS GUIDE, WE WILL COVER:
Overview of Plastic Rotational Molding
Advantages of RotoMolding
Plastic Molding Process Comparison
The Rational Molding Process
Critical Design Considerations for Rotationally Molded Parts
The Nominal Wall… the Frame of your Product
Uniform Wall Thickness
Non-uniform Wall Thickness
Flat Surface Limitations
Parallel wall separation
Requirements for corner angles
Draft angles for easy removal
Designs using internal and external undercuts
Rotational Molding Tooling
Fabricated Molds
Cast Aluminum Molds
CNC Molds
Epoxy Molds
Mold-in-Graphic Options
Typical Projects
Sterling Technologies | 10047 Keystone Drive • Lake City, PA 16423 | 814.774.2500 | SterlingRotationalMolding.com
A ROTATIONAL
MOLDING OVERVIEW
Rotational Molding is a unique plastic molding process
used to produce large hollow parts. Often referred to as
rotomolding, because the molds are slowly rotated in an
oven spreading the resin inside using centrifugal force to
fill the walls of the mold. Depending on the purpose of part,
wall and corner thickness can vary to suit that requirement.
This is critical for water and air tight containers and tanks.
Rotational molding is a versatile manufacturing option with
many benefits over standard thermoform, injection and blow
molding. This process makes it possible to design very large
hollow pieces in virtually any shape, size, color and configuration.
Generally, pieces are lightweight with strong structural integrity.
The process uses a variety of mold types and molding
machines that contain loading, heating and cooling areas.
Once a mold is bolted to one of the machine’s rotating arms,
the pre-measured plastic resin is loaded. Several molds on as
many as three arms can be used at the same time. The molds
then move into the oven and rotate on both the vertical and
horizontal axis. The melting resin adheres to the mold and
lays down a thick even coating, filling in areas that need more
structure. The rotating continues during the cooling cycle
where the part retains an even thickness.
Plastic Molding
Process Comparison
Lost Foam
Molding Reaction Vacuum Forming Twin Sheet Selective Lazer Rapid
Injection Blow Compression Extrusion Rotational Thermoforming Casting
Process Injection (vacuumforming) Foaming Sintering Prototyping
(for making molds)
A parison
Plastic charge is Method of Plastic material is Part is coated and
Plastic is injected (tubular plastic Heated plastic sheet Heated plastic
Heated plastic is Heated plastic is placed in mold Heated plastic sheet Thermoforming that heated with a laser Photosensitive pressed into sand.
Process into mold charge) is is stretched over charge is
injected forced through a die which rotates, is stretched welds 2 plastic sheets until its particles plastic is cured by a Metal (or other
Description into mold
and cures from attached to a mold and suctioned compressed to
creating a long part bi-directionally, over mold into adhere to laser in layers material) is poured
chemical reactions mold and then into the form shape of the mold
in oven one 3D product each other into depression
filled with air
Disposable cups, Pallets, portable

Containers, containers, lids, trays, toilets, housings,
Product packaging, Automotive parts, fuel cells, blisters, clamshells, tanks, air &
Creating small Panels, Enclosures, Concept or highly Making molds and
Ideal Bottles, various speaker casings, textiles, large Tubing, piping, Large/complex vehicle door and ventilation ducts,
and/or critical housings, specific/critical Concept designs duplicates of
Purposes tolerance parts automotive parts
containers car dashboards, pattern pieces fiber optics products, housing, dash panels, enclosures, cases,
tolerance designs concept designs
aerospace enclosures, refrigerator liners, toys, flat and
concept products utility vehicle beds, transportation
and pallets related products
Low Mold
Cost? X X X X X X N/A N/A N/A
Low Unit
Cost? X X X X X
Quick Turn
Around Time? X X X X X
High Strength
Parts? X X X X X
Complex Part
Geometries? X X X X X
Very strong,
Can mold large and Useful for Great for making
flexible, cheap parts.
Quick turn intricate patterns, extremely critical Excellent for molds and rarely
Low mold costs, Fast, cheap Flexibility in Low cost and quick Several finishing and Strong and Stiff, more
Pros around and very
strong flexible parts production molding structures
very low cost, Ultra
turn around production options. flexible parts structural parts
dimensioned scaled down duplicates of parts
detailed parts large basic shape designs, no concept models our of specific
Complex geometries
production mold costs metal materials
are possible.
Weaker parts Only adept at making Limited geomtry,

Very small tolerances Slower processing Very expensive,
than other Long process times, shallow parts, Poor product additional machines Very high costs, Not useful
Weaker parts, VERY limited are difficult to form, and very difficult fragile, cannot be
Cons processes, expensive raw
limited geometry
Processing consistency, heavy
geometry slower than high- to form complex
req’d for various slow process,
easily modified,
for production
Very high material costs can be difficult, flash issues materials, parts size limitations and expensive
speed processes geometries Size Restrictions
upfront costs limited geometry aren’t as flexible
ADVANTAGES OF
ROTATIONAL MOLDING
• Parts originally assembled from several pieces can be
molded as one piece.
• Manufacturers can produce consistent, stress-free wall

thickness and strong outside corners.
• Engineers can select the best materials and additives for

their application making the parts weather resistant, flame
retardant, or static free.
• Designers have the option of adding inserts, threads,

handles, minor cuts and fine surface detail.
• Large and small parts can easily be produced. Since

there is no internal core, minor changes can be made to
existing molds making the process more cost effective.
Parts are formed with heat and rotation, unlike injection
molding, which requires high pressure.
• Material and production costs are lower because

lightweight materials replace heavier and often more
expensive materials.
• Manufacturers can get their product through

prototyping and to market quickly.
ROTATIONAL
MOLDING PROCESS
The rotational molding process uses biaxial rotation and high
temperature to fill the mold and form the plastic part or
component. The rotomolding process is ideal to produce
large, hollow, one-piece parts.
Sterling Tech operates “Carousel” type rotational

molding machines with at least 3 “arms” with multiple
molds positioned on each. In its simplest form, one arm is
being loaded and unloaded, one arm is rotating or spinning
in a gas-fired oven molding the parts, and the third arm is
being air or water cooled. Each arm may contain 2,4,7 up
to 10 separate molds per process cycle. The rotomolding
machine’s arms move independently from one another
allowing a variety of mold sizes with different receipts for
heating and thickness.
Each part being molded has its own recipe for production.
This includes the amount and formulation of the resin,
rotation speed, oven temperature and processing or heating
time. Cycle times can be long... often up to 30 minutes.
With these longer cycle times, rotationally molded parts
typically have run lengths ranging from just a couple to
hundreds of parts with annual order quantities as low as
50 up to thousands of parts.
Ensuring proper product design is critical for manufacturing

and assembly optimization as well as the general success of
the product itself. Rotational molding designs and prototypes
using 3D solid model rendering and rotolog tooling capability
studies are used to help guide customers through the
intricacies of the rotational molding process.
With pending ISO 9002 certification and drawing from
techniques outlined in Six Sigma, World Class and Lean
Manufacturing, Sterling Technologies is dedicated to
delivering superior quality. Process controls include
rotolog tooling capability studies to optimize product
quality throughout the run.
Click Here to watch

Rotational
Molding
Video
DESIGNING A SOUND
ROTATIONALLY MOLDED
COMPONENT
THE NOMINAL WALL... THE FRAME OF YOUR PRODUCT
The nominal wall is the basic frame of your product. It is the
single most important aspect of your design and it must be
handled correctly for quality assurance. The thickness of the
nominal wall will not only determine its strength, but also
its load bearing capability. The thickness will have a direct
effect on the cost of your overall product. The ideal minimum
thickness of .125 inches provides a good compromise
between cycle time, processing ease, strength of product,
and cost.
The rotational molding process permits a designer to change

the wall thickness of their product after the mold has been
built, tested and sampled. This versatility is not common in
other plastic processing techniques.
UNIFORM WALL THICKNESS
The general nature of rotational molding allows the thickness
of the wall to be even throughout the finished part. This gives
designers more flexibility with product design, even with the
most unusual shapes. Although designers have gone as low
as .090-inch wall thickness, a safe .125-inch minimum should
be adhered to.
NON-UNIFORM WALL THICKNESS

Although rotational molding is known for its uniform wall
thickness, non-uniform wall thickness can also be produced
with some limitations. Several techniques are used successfully
to produce items like vertical storage tanks with gradually
thickening wall near the bottom where the weight limit
is greater.
FLAT SURFACE LIMITATIONS
Rotational molds are formed without internal cores,
making it difficult to assure flat space on large panels.
Many experienced designers are able to make adjustments
in designs to accommodate the lack of flatness with the use
of reinforced ribs, providing a .015 inch-per-inch crown on
flat surfaces or using decoration or lettering to mask the
curvature of the product.
PARALLEL WALL SEPARATION

Due to the nature of rotational molding, it is important that
sufficient space is left between parallel walls in a mold
design. The liquid or powered plastic must be in contact
with all surfaces of the cavity to ensure regular cooling times
and preventing molded-in stress. Although a three times
wall thickness separation is achievable, a four to five times
wall thickness separation is recommended.
REQUIREMENTS FOR CORNER ANGLES
In addition to the space needed between parallel walls,
corner angles must also be designed to ensure even wall
thickness throughout an irregularly shaped part. Corners
measuring 90 degrees or more require no special treatment.
Anything under 90 degrees will require special attention and
a closer look at the materials used for the process. Harder
flow materials such as polycarbonate should not be used in a
part requiring angles less than 45 degrees.
DRAFT ANGLES FOR EASY REMOVAL

Draft angles are tapers applied to the part making removal
from the cavity easier. Draft angles reduce the force placed
on a part during the removal and, therefore, minimizing cool-
ing time, cost, induced stress, and part warpage. One advan-
tage that rotational molding has over other molding forms
is that many parts can be manufactured successfully without
using draft angles. As the part cools, it shrinks away from the
mold, making it easy to remove.
There are no specific rules for determining the use of draft

angles. Certain materials such as polyethylene are used for
softer pieces and can be removed without difficulty. However,
the designer must take in consideration the materials used,
shape of the part, and inside shrinking of the piece during the
cooling process. When it does not interfere with the design,
draft angles should be used liberally to ensure easy removal.
DESIGNS USING INTERNAL & EXTERNAL UNDERCUTS
An undercut on a rotationally molded part is any projecting
wall that is parallel to the parting of the mold that must be
deformed in order to be removed from the mold. Because of
the rotational molding process there are design limitations
and material requirements in order to produce an effective
piece. Many times parts are constructed of two or more
pieces to accommodate internal and external undercuts
that are necessary for a product. These extra components,
however, do add to overall maintenance and design costs.
ROTATIONAL
MOLDING TOOLING
ROTO MOLDING USES LOW COST TOOLING
Since the rotational process uses centrifugal force, not
pressure, to fill the mold, rotational molds are relatively low
CRANE HOOKS
cost when compared to other processes like injection and CAST ALUMINUM
blow molding. It is important for customers to choose the MOLD
correct rotational mold for their application. Each type of
mold lends itself to different types of products.
STEEL FRAME
TENSION
SPRING LOADED BOLT
RESISTANCE
ROLLING
COVER
on a
3 sided mold
SPIDER
Frame to support
multiple molds
MOLDS AVAILABLE FOR THE PLASTIC ROTATIONAL
MOLDING PROCESS INCLUDE:
Fabricated Molds are used mainly for large parts with simple
shape fabricated from steel, aluminum or stainless steel these
molds are lightweight, have a consistently thin cavity wall and
are the lowest cost approach when dealing with large molds.
Cast Molds are the most common type of rotational molds

to produce parts varying from very small to large. Cast
molds produce parts that require considerable detail or
elaborate shapes and they can be modified to integrate
design changes.
CNC Molds are used when extreme precision or extended

production runs are required. Because of a higher cost, they
are used only in special cases.
Epoxy Molds use a liquid thermosetting polyester and epoxy

material that is formed and cured at room temperature.
The most important thing to consider with all types of

molding is the quality of the mold. There is no substitute for
an excellent mold. A Production rotational molder can advise
you on the type of mold best for your application, and the
plastic material most suitable for your product. Sterling
Technologies can help you make the right decisions to make
your product stand out from the rest.
MOLD-IN GRAPHICS
ON PARTS
Removed from the rotational mold, parts are quickly
transferred to finishing where the warm flash is trimmed,
assembly holes are drilled and the part is staged for further
operation or is wrapped for shipping. If desired, Sterling will
“flame” the surface to create a smoother more glossy finish
without affecting the quality of your rotationally molded part.
Additional graphic details can be added before or after the
molding process. Mold-in-Graphics can be placed inside the
mold’s cavity prior to molding. These graphics can be large,
colorful and will withstand continued use.
Sterling Technologies also provides a range of other graphic
enhances including hand painting!
Sterling provides:
• Custom trim and cutting operations
• In-mold and post-mold graphics
• Post-mold flaming
• Foam fill and air pressurization
• Air tight pressure testing
• Leak testing
Typical Projects A B
A) The hunter’s package includes a dog kennel, a high-impact case and gun cases.
B) Large enclosures to protect snowmobiles.
C) Fuel cell with molded in threaded fasteners and graphics.
D) Typical case or footlocker. These are common rotationally molded products.
E) Two piece hand washing station with complete assembly.
F) Grocery shopping cart for children. Two peice with molded in graphics.
G) Golf club demo carts with drawers and wheels.
H) Spine boards with foam reinforcement for stiffness.
I) Impact resistant carrying case with handles and wheels.
D E
C
F G H I

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A GUIDE TO

PLASTIC ROTATIONAL MOLDING

Disposable cups, Pallets, portable

Weaker parts Only adept at making Limited geomtry,

• Manufacturers can produce consistent, stress-free wall

• Engineers can select the best materials and additives for

• Designers have the option of adding inserts, threads,

• Large and small parts can easily be produced. Since

• Material and production costs are lower because

• Manufacturers can get their product through

Sterling Tech operates “Carousel” type rotational

Ensuring proper product design is critical for manufacturing

Click Here to watch

The rotational molding process permits a designer to change

NON-UNIFORM WALL THICKNESS

PARALLEL WALL SEPARATION

DRAFT ANGLES FOR EASY REMOVAL

There are no specific rules for determining the use of draft

Cast Molds are the most common type of rotational molds

CNC Molds are used when extreme precision or extended

Epoxy Molds use a liquid thermosetting polyester and epoxy

The most important thing to consider with all types of

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