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.

CAPABILITIES

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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)
 .x_t (Parasolid)

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)

 Polyethylene regrind

Other resins materials used are:

 Nylon

 Polypropylene

 Polycarbonate 

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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

 

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COMPLEMENTARY OPERATIONS

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 heating

 Multi-Stage cooling

 Multi-Stage rotation ratio, rotation angle, and reverse rotation

BENEFITS

logomakr_2pwl9d QUALITY

Priority ONE

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.

 

logomakr_2pwl9d  ATTENTION TO DETAIL

Small things count

Continuous improvement
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.

logomakr_2pwl9d  CUSTOMER SERVICE

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.

logomakr_2pwl9d  DEDICATION

Long-term relationships

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.

logomakr_2pwl9d  ACCOUNT MANAGEMENT

Clear path

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

logomakr_1vmr12  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.

logomakr_0hlv6l  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.

logomakr_7mojwc  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.

logomakr_1vmr12 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.

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