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Industrial Design Blog » Understanding the interrelationships between Design and Rotational Molding
I never overestimate what I know about rotational molding or underestimate its subtleties and their affects on product design. Although the process of rotational molding is appears simple conceptually, it is far from simple in practice. Optimization of numerous processing parameters, tool design and proper material selection present endless challenges to anyone attempting to mold quality parts. Although a designer isn’t required to understand the details of rotationally molding quality parts, I believe it is extremely beneficial to gain a clear understanding of the process. I urge designers to observe parts they have designed being molded for the first time. There is much to learn and you will gain a greater appreciation for the interrelationships between part design, tooling and the process.
Recently I had the opportunity to see a product I designed being trail molded at a reputable molder. Although I’ve visited many rotational molders, I’ve never seen a facility like this one. It was very large, well organized and impressively laid out. During the molding trial I carefully observed how the mold was being handled and how inserts were installed. I witnessed the process of removing the part from the mold and how my provisions for draft aided in part removal. Examination of the physical mold with its steel frame, clamps and removable inserts improved my understanding of part design and its affect on tooling. During the molding process I was trying to distinguish the boundaries between part design, tool construction and processing in regards to overall part quality. It became very apparent that processing and resin selection play a major role in final part quality. It is therefore extremely important to provide molders with a well designed part to maximize their chances of consistently molding quality parts.
My numerous experiences during mold trials continually remind me of how important our roles as designers are to the successful production of a finished product. Although most of us are not at the press molding the parts we designed, our choice of resin, overall product shape and more importantly part details have a major impact on production. If we keep an open mind to design improvements and are curious about the subtitles of the rotational molding process, our designs will only improve. I find myself continually asking questions to shop floor workers, plant managers, as well as the owners of molding operations about how they perform specific tasks. All this knowledge aids me in designing the next product. I urge all designers to look at other products and ask those involved in their development to explain the product to you. This is how you will learn to improve yourself and the next product you design.
Remember product design is an endless journey throughout which we are seeking a better way to design an existing product or introduce a totally new product. These achievements can only be successfully attained by applying our imaginations to a vast knowledge base which has been amassed by asking questions, observing and most importantly being curious. So next time you have an opportunity to see your product being molded, seize it!