Competences

Consultancy in all aspects of rotational moulding.

Consultancy in design, mould, raw material, machine, production and quality, after 20 years of professional experience.

Perform error analyses to diagnose and suggest solutions.

Conduct process improvement studies.

Optimizing heating and cooling time.

Recommend raw materials specific to the product, application or conditions.

Propose mould release agents.

Determine the right process time for qualitative and efficient production of the part according to the specified raw material and wall thickness.

Assistance in the production of PE-Foam (making moulds and arranging equipment suitable for polyethylene foam production. Production method recommendation for providing desired technical conditions at lower cost by using polyethylene foam in products that require rigidity or insulation)

Support new product commissioning.

Revising the existing production line or planning a new line for increasing efficiency.

agreement-team-friend-collar-white_1262-2253

2 . Part design

Visual and functional CAD design of the finished part.

3 . Adaptation of an existing product to the rotomolding technique

Engage in transformation studies for the re-production of an already existing product which formally consisted of a different material (steel, sheet metal, wood, concrete, etc.) but shall be re-engineered to rotomolded plastic.

4 . Product improvement

The product is technically evaluated through experienced eyes.

The product is analysed by means of FEA.

Obtained results are shared with the customer.

When necessary, changes are made in the design.

5 . POKA-YOKE

POKA-YOKE, “mistake-proofing, or inadvertent error prevention” is completed prior to the manufacturing of each mould. Employment of this step enables the operator to foresee anticipated errors and prevent them in advance.

6 . Mould design

There are many factors to consider, as well as certain challenges to overcome, when designing moulds. Some of which include: improving the quality of the parts, reducing the weight, aiming a long mould life while keeping the wall thickness of the mould thin, and the weight of the frame light. What ameliorates this process is being cognizant of the pros and cons of rotational moulding, and reflecting on the necessities for a mould.

7 . Mould frame design

The answers to the following 4 questions are kept in mind while designing a mould frame:

1 . What type of machine will the mould be operated in?

2 . What type of arm (straight, L, or C type) will the mould be fastened on?

3 . What direction will the mould be opened to?

4 . How is the mould to be unloaded? With an overhead crane or a scissor lift table.

8 . Mould fabrication

Sheet metal mould

Stainless steel mould

Cast aluminium mould

Machined aluminium moulds

9 . Mould frame manufacture

A most suitable, durable, and lightweight frame is designed during the mould design stage.

10 . Fixture design & manufacture

Cooling fixture

Checking fixture

Assembly fixture

11 . Equipment design & manufacture

Cutting & drilling equipment

Welding equipment

12 . Special welding machine design & manufacture

Hot plate welding machine

Spin welding machine

13 . Burrless production

Burrs due to drilling operations can remain especially inside plastic fuel tanks. We can prevent the formation of these burrs and even eliminate the drilling work with a special material to be used in the mould.

14 . Mould approval

Mould measurement report

3D measurement report (CMM)

Trial production / sampling

15 . User manual

Before delivery, a user manual is prepared for each mould. This manual indicates some information such as how to open the mould, the locations of the inserts inside...etc.

16 . Post-delivery services

Start-Up (mould commissioning and process optimization)

Periodic mould maintenance.