Rma Rotomolding Guide 20110701

Ravago Manufacturing Americas
13001 Almeda Road

Houston, Texas 77045
713-433-5604 Fax 713-433-9783

The technical information, suggested uses and applications presented are made without charge and are believed to be reliable; however Ravago Manufacturing Americas disclaims responsibility
for results of use of this information. Ravago Manufacturing Americas makes no warranties, either expressed or implied, concerning our materials, including any warranties of merchantability or
fitness for a particular use. All users should rely upon their own tests in determining suitability.

13001 Almeda Road, Houston, TX 77045 Tel: (713)433-5604
TECHNICAL NOTE
Rotational Molding Guide

Introduction:
Rotational molding is a process where plastic materi-
als are formed into useful articles by rotating a mold
containing the plastic material in an oven sufficiently
hot to melt the plastic. The mold is rotated in two
directions to cause the plastic to coat all surfaces of
the mold. There is little pressure inside the mold dur-
ing the forming process. After the plastic is thorough-
ly melted to coat the mold surface the mold and plas-
tic is cooled, the part is removed from the mold.
The rotational molding process is ideally suited to
fabrication of hollow parts. It also lends itself to pro-
duction of rather large parts. The process can ac-
commodate articles with complex geometry.
Because the process is carried out at low pressure, the
molds can be fabricated from relatively inexpensive
materials. The relatively low cost of tooling allows
rotational molding to be used to produce parts whose
production volume would not amortize the high cost
of expensive injection or blow molds.
At first examination, the rotational molding process
seems simple. Those who have had experience pro-
ducing parts by rotational molding understand that the
rotomolding is a complex manufacturing process,
with many variables that can affect the quality articles
produced.
Polyethylene is a particularly good material for rota-
tional molding. When used as a fine mesh powder,
polyethylenes melting characteristics easily form a
solid part. Polyethylene has adequate heat stability to
withstand the relatively high temperature and long
heating cycles of rotational molding. Parts formed
from polyethylene have an excellent combination of
strength, toughness and other mechanical properties.
In order to optimize the properties, it is necessary to
use proper molding conditions to form articles.
Muehlstein rotational molding products are designed
for optimized processability and properties in rota-
tional molding. These products are compounded from
prime quality materials by a process designed to yield
consistent material, box-to-box and shipment-to-
shipment.
This bulletin is designed to help the customer find the
optimum molding conditions for their application.
Because of the diversity of article made by the rota-
tional molding process and the different types of rota-
tional molding machines and molds used in the roto-
mold process, it is impossible to establish universal
optimum molding condition that are optimum for all
circumstances. We can offer recommendations for
starting conditions and guidelines for adjustments to
the process conditions to help optimize the process
for the particular part being molded.
Process Control:
In order to achieve consistent quality rotationally
molded articles, it is important that proper molding
conditions are used and, as with any manufacturing
process, that all variable in the manufacturing process
be controlled as closely as possible. Each rotational
molding cycle must be preformed under the same
conditions as the previous cycle, as nearly as possi-
ble.
Because different parts are often placed on the same
arm or different arms of a multi-arm machine, often
the molding cycle is a compromise to achieve ac-
ceptable quality for all parts being molded.
Mold Design:
Proper mold design is critical for production of quali-
ty parts. While the design of molds is outside the

Page 2 Ravago Manufacturing Americas 20110701
scope of this guide, there are a couple of areas of
mold design that should be highlighted.
Mold Venting:
Mold venting is important to good part quality. Prop-
er venting will allow the part to be heated and cooled
at about atmospheric pressure. This will eliminate
blowholes at the parting line. Proper venting will pro-
long the contact of the cooling part with the inner
surface of the mold, resulting in a shorter cooling
cycle and post-mold warpage. Lower pressure differ-
ential also results in longer mold life.
In general, mold vents of sufficient size and number
to allow equalization of the inner mold pressure. Vent
tubes should extend to the center of the mold. The
inside end should be loosely packed with fiberglass to
prevent the unfused powder from exiting the mold
early in the heating cycle.
In order to be efficient vent tubes must be kept clean.
If the fiberglass becomes clogged with plastic powder
the vent tub will no longer function to equilibrate
pressure.
Drying:
Polyethylene does not absorb moisture easily. There-
fore, under normal conditions, pre-drying of the pul-
verized powder is not required. Under high humidity
conditions, or when specialty grades, such as flame
retardant, are used drying may be necessary.
Measurement of Charge
Production of consistent parts requires that each step
of the rotational molding process be repeated precise-
ly every cycle. This is especially important that the
same weight of polymer be added to the mold for
each part. The bulk density of pulverized polyeth-
ylene for rotational mold has some variability. There-
fore, material should be measured on a weight rather
than a volume basis.
Oven Temperature:
Proper cure of the rotationally molded part requires
sufficient heat to melt the polyethylene for long
enough time duration to completely fuse the polyeth-
ylene. The oven temperature must not e so high that
the polyethylene is oxidized. On a multi arm machine,
the heating and cooling cycles must be of equal time.
On one hand, the molder would like the oven temper-
ature to be as high as possible to shorten the heating
time to a minimum. On the other hand, keeping the
oven temperature as low as possible gives optimum
part appearance, part toughness, reduces the cooling
required and reduces thermal stress on the mold. The
rotational molder must decide what combinations of
these variable results in acceptable part quality and
productivity.
Starting Conditions:
Our experience has shown that the following condi-
tions are good starting points. The molders experi-
ence with existing molds and specific molding ma-
chines may suggest slightly different conditions. In
general, Muehlstein polyethylene rotational molding
compounds can be processed at 50 to 75F lower
oven temperatures than competitive polyethylenes,
especially if a Muehlstein precolored polyethylene is
replacing a dry-blended color.
Oven temperature: 500 to 600F
(260 to 315C)
Oven time: 10 to 25 minutes

You can reduce the trial and error involved in
time/temperature parameters by measuring the PIAT
(Peak Internal Air Temperature). The following table
is a general guide for PIAT for RMA standard resins.
These are suggested for a wall thickness of around
0.125 in and adjustments will need to be made for
thinner or thicker walls:
Table 1.
GRADE PIAT C
HMP-304 210
HMP-305 200
HMP-307 190
HMP-301 215
HMP-315 204
HMP-325 202
AQUATUF HMP-334 205
AQUATUF HMP-337 207
Cooling
Like heating cycles, there is no universal best cooling
cycle. For a multi-arm molding machine, the cooling
time can be no longer than the heating time. On the
other hand, high cooling rates increase the potential
for warped parts.
It is usually best to start the cooling with several
minutes of air-cooling. This is followed by atomized
water, air/water or water spray for the bulk of the
cooling time. It is beneficial to finish the cooling cy-

cle with several minutes of air cooling, allowing the
outside surface of the mold to dry.
Polyethylene is semi-crystalline polymer. The degree
of crystallinity is partly controlled by the cooling rate
of the part. Rapid cooling results in lower crystallini-
ty. Unfortunately, rapid cooling produces parts with
low crystallinity at the mold side of the part and high
crystallinity at the inner surface of the part. This dis-
parity manifests itself as warpage.
It has been found that warpage is minimized with
slow cooling. This must be accomplished with the
constraints of the cooling time available. Slow cool-
ing may adversely affect other physical properties,
such as impact strength.
AQUATUF Higher density, high performance res-
ins in the 0.942 to 0.952 range tend to be more crys-
talline and have a higher shrink rate. These may need
to be cooled more slowly to prevent warpage, and
every attempt made to hold the part against the mold
surface until the release point [This is best determined
by a Rotolog type trace on the cooling cycle].
Common problems:

Part Surface:
Several factors should be considered when at-
tempting to improve the quality of the parts sur-
face.
The surface of the part can be no better than
the surface of the mold.
Mold design is also of importance in the
production of part especially in parts with
recesses, high definition or inserts.
Selection of the appropriate melt index poly-
ethylene is another factor.
The dry flow and particle size distribution of
the molding power will also affect surface
quality.
The selection of the proper combination of
heating and cooling conditions is also im-
portant factors.
Rotation speed and rotation ratio effect part
surface quality
Consistent application and minimum use of
mold release.
References:
1. Introduction to Rotational Molding Seminar,
Dr. Glenn Beall, Association of Rotational
Molders, Chicago IL.
2. Rotational Molding Troubleshooting Manual,
(ARM-102-1089), Association of Rotational
Molders, 1989, Chicago, IL


Typical Rotation Ratios Typical Speed
(RPM)

Ratio

Shapes
Major
axis
Minor
axis
8 to 1 Oblongs (Horizontal)
Straight tube (Horizontal)
8 9
5 to 1 Some defroster ducts 5 6
4.5 to 1 Balls & gloves 8 9.75
3.3. to 1 Any shape having overlap-
ping lines of rotation at 4
to1
10
12
12.25
14.5
4 to 1 Cubes, balls or odd shapes
Rectangular boxes, horses
with bent legs
8
10

10
12.5
2 to 1 Rings, tires, balls
Any rectangle that shows
two or more thin sides
when run at 4 to1
Picture frames, Round flat
shapes
Horses with straight legs,
Auto crash pads (vertical)
6

8

10

12
9

12

15

18
1 to 2 Parts that should run 2 to 1
but show thin side walls.
5
7
15
21
1 to 3 Flat rectangles e.g. gas
tanks, suitcases, tote bin
covers, etc.
4
6
9.5
15
22.5
36
1 to 4 Tires, curved air ducts, Pipe
angles, flat rectangles, Balls
whose sides are thin at 4 to
1.
4
5
6
20
25
30
1 to 5 Cylinders, vertical 4 24
Vertical - Mounted parallel to major axis
Horizontal - Mounted perpendicular to major axis.
Rotational Molding Trouble-shooting Guide
Problem Probable Cause Possible Solution
Warped
parts
Inadequate venting Provide adequate
venting - 3/8-1/2
diameter vent per ft
3

of molded volume is
suggested for thin
walled parts.
Non-uniform cooling
of part caused by resin
pulling away from
mold.
Rotate mold during
cooling cycle. Provide
adequate venting and
make sure vents are
not clogged. Use less
mold release. Check
for too effective mold
release agent. Avoid
large flat panels in
part design if possible.
Reduce cooling rate
during initial part
cooling cycle. Increase
the cooling medium
temperature, air cool,
and then water cool.
Apply air pressure
through spine during
cooling
Non-uniform cooling
caused by uneven wall
thickness in the part.
See suggested reme-
dies under problem
heading Uneven wall
thickness of molded
parts.
Non-uniform cooling
caused by sections of
the mold being
shielded from heat
and cooling medium.
Mount mold to elimi-
nate shielding prob-
lems, add baffles to
direct heat and cool-
ing into recessed or
shielded areas.
Uneven cooling
caused by clogged
water nozzles
Check and clean noz-
zles on a periodic
schedule.
Over-cured part. Deg-
radation of the resin
due to high tempera-
ture and/or excessive-
ly long heating cycle.
Decrease oven tem-
perature or heating
time.
Highly under-fused
part. Some degree of
under-fusion is advis-
able especially in the
case of low melt-index
resins to prevent deg-
radation; however,
highly underfused
parts can cause signif-
icant loss of impact
strength.
Increase oven temper-
ature or total heating
time. Increase heat-
transfer coefficient,
e.g. steel or aluminum.
Improper coloring Select pigment and
pigment loading that
does not affect resin.
Use precolored, com-
pounded resin.
Resin type Use proper resin hav-
ing adequate melt
index and molecular
weight distribution for
application.
Moisture on resin or
pigment.
Only use dry powder
and/or pigment.
Poor
impact
strength
Resin selection not
correct
Use lower density or
lower melt index resin
Density increase dur-
ing slow cooling
Increase cooling rate
to maintain a lower
density.
Part design not ap-
propriate
Review and alter mold
design if necessary,
eliminate sharp cor-
ners and narrow pas-
sages.
Insufficient fusion of
resin
Increase oven time
and/or temperature.
Improper coloring Select pigment and
pigment level that
does not effect im-
pact. Use pre-colored,
compounded resin.
Over-curing of resin.
Degradation of resin
due to long-term high
temperatures.
Decrease oven tem-
perature or heating
cycle.
Parts
sticks in
the mold
Insufficient amount of
mold release agent or
the release agent has
deteriorated with use.
Reapply or use more
release agent. Old
release may have to
be removed and a
new one applied.
Ineffective release
agent or mold release
does not withstand
elevated tempera-
tures.
Use suitable mold
release agent that is
effective for resin and
temperature used.
Apply according to
suppliers instructions.
Mechanical interfer-
ence during part re-
moval
Locate mold parting
line at undercut or
taper side walls of
mold.
Roughness and poros-
ity of mold surface
provide areas where
resin may adhere.
Refinish damaged
mold surfaces, plug,
weld and sand
smooth.
Presence of resin at
parting line due to
internal mold pressure
forcing semi-molten
Provide adequate
venting, 3/8 to
diameter vent per
cubic foot of mold
resin through parting
line.
volume is suggested
for thin walled parts.
Build-up of degraded
resin in the mold may
be caused by burning
of thin walled sections.
Clean mold periodical-
ly. Reduce oven tem-
perature.
Shrinking onto large
deep inserted areas.
Provide adequate
taper to mold walls.
Use effective mold
release on insert are-
as. Remove part while
warm. Provide ade-
quate means for ap-
plying force to sepa-
rate mold halves.
Undercuts in mold Design mold to place
undercuts at parting
linen so that mold has
draft angle for part
removal.
Low shrinkage value
for resin.
Use higher density
polyethylene grade.
Blow
holes
through
the part
or ring-
worm
effect
under
thin wall
surface
other
than at
Porosity in the cast
aluminum mold
Obtain better quality
castings. Drill through
void and drive pin or
weld from inside.
Relieve from outside
by drilling into void.
Remove parts from
molds while warm to
touch. This helps drive
moisture out of pores.
the part-
ing line
Pores or holes in
welds.
Use proper welding
rod and procedure.
Weld inside surface
first to get good
penetration.
Excessive
flashing
at mold
parting
line.
Internal mold pressure
during heating cycle
tends to force semi-
molten resin out
through the parting
line.
Provide adequate
venting and make sure
vents are not clogged.
Remate mold parting
line and adjust mold
clamp pressure evenly.
Clean mold flange to
prevent gapping and
apply new mold re-
lease on flange. Re-
duce internal air pres-
sure if used. Use lower
melt index pressure.
Bubbles
on the
mold
parting
line.
During the first stages
of cooling, there will
be a rush of air into
the part to fill the
resultant partial vacu-
um. If there is inade-
Vent the mold to at-
mosphere pressure.
Relocate vent to mid-
dle of mold. Use glass
wool in vent. Use
Teflon as vent tube.
quate venting, air will
penetrate the molten
resin, at parting line,
becoming trapped as
the part wall solidifies.
Make sure tube is
adequate size.
Poor mold parting
line.
Remate molding part-
ing line and adjust
mold clamp pressure
evenly. Clean mold
flange to prevent
gapping and apply
new mold release on
flange.
Discol-
oration of
interior
surface of
part.
Degradation of resin
due to high tempera-
ture and/or excessive-
ly long heating cycle.
..
Decrease oven tem-
perature or heating
cycle, or purge part
with inert gas (nitro-
gen). Use resin with
the proper amount
and type of antioxi-
dant. Check pigment
for heat stability.
Powder
bridging
or not
filling
narrow
passages
of mold.
Mold design incorrect. Modify mold by in-
creasing width to
depth ratios across the
mold opening. Design
corners of mold with
more generous radii.
Avoid ribs with less
than 4x wall thickness.
Poor pourability (dry
flow) of powder.
Make sure powder has
acceptable pourability
and bulk density.
Powder does not melt
or flow properly.
Use finer mesh pow-
der or resin with a
higher melt index.
Cold spots on mold. Avoid any shielding
mold areas. Check for
mold wall thickness
uniformity.
Improper mold rota-
tion.
Use correct ratio and
rotation speed.
Poor part
stiffness
Part wall too thin Add more powder to
initial charge.
Resin selection not
correct.
Use rein of higher
density.
Part design not ap-
propriate.
Review and alter mold
design if necessary.
Under fused parts. Increase oven temper-
cycle. Increase heat-
transfer rate by using
thinner mold walls, or
make the mold from
materials of greater
heat-transfer coeffi-
cient, e.g. steel or
aluminum. Try filling
molds while hotter.
Light-
ning
effect in
Moisture in pigment
or resin.
If dry-blending, dry
pigment or use pig-
ment from unopened
colored
parts.
container. Use pre-
compounded color
resin powder. Dry
resin completely or
replace.
Static build-up Add small amount of
mineral oil to resin or
commercially available
anti-stat. Make certain
that all mixing and
molding equipment is
adequately grounded
with high surface cop-
per cable.
Pigment not ground
properly.
Use 100-mesh pig-
ment or pulverize
pigment prior to mix-
ing. Use pre-
compounded color
resin powder.
Blow
holes
through
part
around
insert
Poor fit on inserts
allowing moisture or
vapors to be trapped
around insert and
expand, blowing a
hole in the part.
Refit insets and relieve
to allow trapping
gases to escape to the
outside of the mold.
Drill a small hole
through the insert bolt
to relieve gas pres-
sure.
Bridging of resin be-
cause of close dimen-
sions.
Change insert dimen-
sions or location to
allow powder to flow
without bridging.
Speckled
colors
and
lumps of
pigment
in dry
blended
colors
Insufficient blending Break up agglomer-
ates of pigment be-
fore blending. Use
high intensity mixer. If
unable to achieve a
desirable color bal-
ance, use a com-
pounded color resin
powder.
Long
oven
cycles
Heat-transfer rate not
adequate to melt all
resin, excessively thick
mold.
Increase heat-transfer
rate by using thinner
mold walls, or make
the mold from materi-
als with greater heat-
Heating not efficient. Increase air velocity
around mold during
heating cycle. Check
oven for air leaks.
Low oven tempera-
ture.
ature. Recalibrate
instruments on regular
schedule.
Resin powder too
coarse
Use finer mesh pow-
der
Poor melt flow Use higher melt index
resin.
Extended cooling Reduce air-water cool-
ing ratio
Long-
term part
failure
Part over-cured during
molding
Decrease oven tem-
perature or heating
cycle
Photo-degradation of
part caused by ultra-
violet light from sun
or internal lighting
(florescent)
Use UV stabilized resin
in application. Add
suitable UV stable
pigment.
Stress-cracking due to
multi-axial stresses in
part. Cracking may
have been accelerated
by chemical environ-
ment and/or tempera-
ture
Use polyethylene
grade with good envi-
ronmental stress crack
resistance (ESCR).
Modify design around
the areas containing
inserts. Examine parts
in field use to deter-
mine adequacy of
design around stress
concentration points.
Inadequate resin addi-
tive system.
Antioxidant type and
level of concentration
may be inadequate.
Reduce level of inter-
nal mold release if
used.
Color change due to
oxidation. Light col-
ored parts may look
yellow or pink.
Reduce oven tem-
perature.
Improper colorants or
blending.
Use colorants that
disperse well in base
resin. Use pre-
compounded color
resin powder for op-
timum dispersion of
color and stabilizers.
Uneven
wall
thickness
of mold-
ed parts.
Improper mold rota-
tion
Vary ratio and speed
of rotation of mold to
obtain even coverage
and adequate number
of powder trackings
Mold shielding Mount mold to elimi-
nate shielding.
Uneven mold wall
thickness
Use care in designing
molds to prevent
excessive variations in
mold wall thickness
(thin spots attract
more resin)
Inadequate powder
properties. Low bulk
density, no powder
pourability, large
amount of fluff, parti-
cles have many tails
that entangle into
clumps during mold-
ing.
Obtain an acceptable
quality powder. F
using bulk powder
storage, empty stage
silos before refilling to
prevent accumulation
of fine particles in
storage silo.
Buffeting or air flow in
deep dished areas.
Avoid deep dished
areas whenever possi-
ble. Reduce thickness
of mold in dished
areas. Open handles
so air can flow
through kiss-offs in
mold.
Highly
under-
fused
parts,
with
Oven temperature not
high enough to drive
air bubbles out of part
walls.
cycle.
many
small
bubbles
in wall or
rough
powdery
inside
Heat transfer rate not
adequate to melt
resin.
Increase heat transfer
rate by using thinner
mold walls or make
mold from materials
with greater heat-
surface. Resin powder too
coarse.
Use finer mesh pow-
der.
Moisture in mold Reduce moisture in
mold by running with
warm molds and dry
mold before charging
powder.
Poor
flow-out
into mold
recesses
Poor mold design Design shallow re-
cesses with generous
radii on edges. Pre-
heat recessed areas
with torch for 30-
seconds before charg-
ing. Add heat deflec-
tors or thermal pins.
Improper mold rota-
tion
Change ratio and/or
speed of rotation.
Melt index of resin too
low
Increase melt index of
resin.

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