ROTATIONAL MOLDING MANUFACTURING
Rotational Molding is a thermoplastic process that produces hollow parts by placing powder resins such as polyethylene into a mold that rotates biaxially in an oven until the resin melts and coats the inside of the mold. The hot mold is cooled while it continues rotating to create an even coating of plastic throughout the mold that yields a one-piece, seamless part.
PART DESIGN & ENGINEERING SERVICES
Our in-house engineering team will oversee your project from inception to production.
Our goal is to develop a long-term partnership with all of our customers is to add value to their current business, and to ensure that new projects’ launch as seamless as possible.
Whether it is a concept, 3D model, or an idea, we are here to support your efforts to ensure that your project is a success.
Engineering Supported File Formats:
.sldprt (Solidworks part file)
.iges or .igs (Initial Graphic Exchange Specification)
.step or .stp (Standardized Graphic Exchange Format)
MATERIALS- POLYMERS AND RESINS
Polyethylene is the main type of materials used in rotational molding manufacturing.
Some of the most common resin materials used are:
Low-density polyethylene (LDPE)
High-density polyethylene (HDPE)
Cross-linked Polyethylene (XLPE)
Fire retardant polyethylene (FRPE)
Other resins materials used are:
ROTATIONAL MOLDING ADVANTAGES
Stress free, one-piece parts
Uniform wall thickness
Design flexibility allowing for complex geometry
High impact strength
Phenomenal dimensional stability
Molds are simple, cost-effective and can be fabricated with a short lead time
Intricate details, variety of textures, high gloss finishes
Virtually any size piece can be rotationally molded
Expeditious process from concept to market
Rotational molding offers a product designer the opportunity to manufacture a wide array of imaginative composite assemblies.
Project Development: Idea -> Specifications -> Design -> Part Rendering - > Manufactured part
Adding fasteners, graphics, and foam capabilities
Plastic or metal molded-in, threaded inserts
Double wall components are achievable
Complete in-house mold maintenance
Finite Element Analysis (FEA)
3D printing prototyping capabilities
ROTATIONAL MOLDING EQUIPMENT
Forté Products utilizes FERRY Rotational Molding equipment-independent carousals to large rock and roll machine. Capacity to run small to large parts. From a small fuel tank, to parts 23FT in length
All of the equipment we utilize have process controls such as:
Multi-Stage rotation ratio, rotation angle, and reverse rotation
Quality based on ISO9000/AS9000 standards
Forté quality systems are based on stringent military, FAA and major corporation standards. Quality is tracked and reported continuously, throughout the day, resulting in better rates/results compared to industry norms.Critical Data Sheets, detailed work instructions and a First Article Inspection documentation/approval process assure consistency for your parts and products.
ATTENTION TO DETAIL
Small things count
Forté operations are guided by Key Performance Indicators (KPI’s) that review critical data and performance weekly. KPI feedback is used to best assure all aspects of your projects, and our performance, are working toward improvements and results that exceed your expectations. No detail is too small.
Second to None
Committed to YOU
Forté customer service is your most recognized and proven benefit. Forté makes doing business with us easy. Our communication, our experience and our response time make the difference for you. Challenges are addressed and resolved quickly. Just ask our current, loyal customers.
Guarding your reputation
Forté enjoys long-standing and valued partnerships with companies who are proud to place their name and reputation on parts and products we manufacture for them.
Forté is honored that many customers have been with us for 30+ years.
On Call 24/7
Account Managers are your dedicated resource to anything and everything Forté . Our account management structure guides your projects through development to implementation and is never ending.
ROTATIONAL MOLDING PROCESS
STAGE 1 - LOAD/UNLOAD -
A pre-measured 35 mesh powdered resin, colored or natural, is loaded into an open cast aluminum or stainless steel mold. The two halves of the mold are closed and clamped together. Several molds can be mounted together on a framework or a spider grid on an arm.
STAGE 3 - COOLING CHAMBERS-
The arm with molds is indexed to cooling chambers where air or water, or both, cool the molds, and finished part inside the mold, to a desired temperature, over a desired amount of time. The molds continue to rotate slowly about two axes.
STAGE 2 - OVEN -
The arm with molds is indexed into a heated oven where the molds rotate slowly about two axes after the oven door is closed. The powdered resin cascades to the heated, inner walls of the molds, melts and forms layers, to the desired wall thickness, of the parts being molded.
STAGE 4 - LOAD/UNLOAD-
The molds are opened on the load/unload platform and the finished,molded parts are removed. The finished part is transferred to a finishing area where desired secondary operations, such as routed openings, band saw cuts, parting line finishing and other operations, are performed.
DRAINAGE DITCH END WALL
FURNITURE / DISPLAYS
CROSSING GUARD CADDY
FOOD SERVICE CART
STABLE I COMPLIANT I EXCHANGEABLE Our client designed a system to significantly reduce the time and effort involved with common drainage installations. The product had to be durable, stable, resistant to salt, chemicals and harsh environmental conditions and meet DOT and ASTM requirements. Forté manufactures three sections of the Endwall Drainage System that have proven successful in over 1,500 installations in the United States and Canada.
STRONG I RELIABLE I PERSONALIZED The original and leading provider of Bumper Post Sleeves in the industry takes full advantage of Forte Products’ mold-in and mold-on graphics capability to customize their product for a wide variety of customers. Further, Forte assists the client with intelligent inventory management to meet ever expanding customer needs.
DISTINGUISHED I SPECIFIED I NOTICEABLE When first conceived, these designer table pieces brought challenging features to the rotational molding process. Forte resolved the issues and molded parts that look exceptional wherever they are used.
STABLE I INTEGRAL I LONG LASTING These spa steps are dual purpose serving both to enable entry into a spa and also to provide storage space for towels, toys and spa cleaning products. Proper assembly is assured by Forte’s precise molding capabilities.
INNOVATIVE I GUARDED I CONTAINED Safety for children in school crosswalks was the primary motivation for the customer’s innovative Crossing Caddy. Forte’s design and engineering group was instrumental in developing the hinged door component of this Caddy.
SAFE I INVENTIVE I ACCOMMODATING With zero compromise for safety and insistence on exacting assembly, our customer relies on Forte to deliver theme park Strollers that perform as intended each time they are used.
STRUCTURED I DEPENDABLE I DEMANDING The largest part manufactured at Forté, the Vault meets stringent environmental specifications for durability and structure.
LONG-LASTING I SECURE I PLANNED Next time you attend a college or professional sports event, you may just be sitting in a Stadium Seat produced and finished at Forte Products.
DURABLE I STABLE I ADAPTABLE This large rotationally molded Housing is just one component used in the assembly of our client’s portable evaporative cooler found in factory shops, loading docks, greenhouses, garages, sporting events, livestock buildings, even outdoor dining areas like a company picnic.
VISIONARY I RESOURCEFUL I PIONEERING Dissatisfied with their past supplier, this customer transferred their tooling and production to Forte Products. Forte established an assembly work cell that assures quality and consistency in production. Since then, the customer called upon Forte to help develop and manufacture a second innovative Cooler.
SPECIALIZED I CONSISTENT I FUNDAMENTAL Demanding quality, specialized materials and parts manufactured for durability are on-going requirements of this patented Food Service Cart.