Here are other 4 possible solution to our problem
GRP - Glass Reinforced Plastic hand lay up process:
the most common and least expensive open-moulding method because it requires the least amount of equipment. Fibre reinforcements are placed by hand in a mould and resin is applied with a brush or roller. This process is used to make both large and small items, including boats, storage tanks, tubs and showers.
The concerns regarding this method are that since it involves manual operating, there are safety hazards which need a level of supervision.
It could be learnt after a short training but takes time to perfect the craft and have an extremely good finished product.
Rotational moulding :
The rotational moulding process consists out of four phases-loading, heating, cooling, remove, see image below.
It all starts with filling the mould with powdered resin. The inside of this mould is the negative of the final product. The moulds are usually manufactured from aluminium, on CNC machines.
the mould moves to the next stage, where it is heated to 300oC. At the same time, the mould rotates so that the powder is forced against the wall of the mould. The mould moves onto the cooling stage. Cool air is blown around the mould, aided by large fans. The mould cools slowly and solidifies. The finished product is then removed
Vacuum forming(Thermoforming):
The process involves heating a plastic sheet until soft and then draping it over a mould. A vacuum is applied sucking the sheet into the mould. The sheet is then ejected from the mould. In its advanced form, the vacuum forming process utilizes sophisticated pneumatic, hydraulic and heat controls thus enabling higher production speeds and more detailed vacuum formed applications.
Blow moulding:
The process is similar to injection moulding and extrusion.
1. The plastic is fed in granular form into a 'hopper' that stores it.
2. A large thread is turned by a motor which feeds the granules through a heated section.
3. In this heated section the granules melt and become a liquid and the liquid is fed into a mould.
4. Air is forced into the mould which forces the plastic to the sides, giving the shape of the bottle.
5. The mould is then cooled and is removed.
In conclusion, Rotational moulding would be the best method out of four. It is because it costs less than vacuum moulding and blow moulding and it is flexible at production volume which is significant as the production of the prototype of the rotor should be low volume and it can be automated which means the operator doesn't require extensive training to work the machine.
GRP - Glass Reinforced Plastic hand lay up process:
the most common and least expensive open-moulding method because it requires the least amount of equipment. Fibre reinforcements are placed by hand in a mould and resin is applied with a brush or roller. This process is used to make both large and small items, including boats, storage tanks, tubs and showers.
The concerns regarding this method are that since it involves manual operating, there are safety hazards which need a level of supervision.
It could be learnt after a short training but takes time to perfect the craft and have an extremely good finished product.
Rotational moulding :
The rotational moulding process consists out of four phases-loading, heating, cooling, remove, see image below.
It all starts with filling the mould with powdered resin. The inside of this mould is the negative of the final product. The moulds are usually manufactured from aluminium, on CNC machines.
the mould moves to the next stage, where it is heated to 300oC. At the same time, the mould rotates so that the powder is forced against the wall of the mould. The mould moves onto the cooling stage. Cool air is blown around the mould, aided by large fans. The mould cools slowly and solidifies. The finished product is then removed
- Low investment costs compared to vacuum moulding or blow moulding.
- There is great production flexibility with the process.
Vacuum forming(Thermoforming):
The process involves heating a plastic sheet until soft and then draping it over a mould. A vacuum is applied sucking the sheet into the mould. The sheet is then ejected from the mould. In its advanced form, the vacuum forming process utilizes sophisticated pneumatic, hydraulic and heat controls thus enabling higher production speeds and more detailed vacuum formed applications.
Blow moulding:
The process is similar to injection moulding and extrusion.
1. The plastic is fed in granular form into a 'hopper' that stores it.
2. A large thread is turned by a motor which feeds the granules through a heated section.
3. In this heated section the granules melt and become a liquid and the liquid is fed into a mould.
4. Air is forced into the mould which forces the plastic to the sides, giving the shape of the bottle.
5. The mould is then cooled and is removed.
In conclusion, Rotational moulding would be the best method out of four. It is because it costs less than vacuum moulding and blow moulding and it is flexible at production volume which is significant as the production of the prototype of the rotor should be low volume and it can be automated which means the operator doesn't require extensive training to work the machine.
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