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the Technology Interface/Spring 2008 Klein commercially made juggling club and compared its size to our design. Since our product was larger, we increased this amount slightly to give us a starting point. This amount of material was placed in the mold and the mold was bolted closed. The mold was then secured in the rotational molder; in this case we used a Ferry M 20 Clamshell machine as shown in Figure 30. Since we chose HDPE for our material, we needed to determine the proper machine set up data. The critical factor in the cycle is to have the material reach and hold its optimal processing temperature for the appropriate amount of time. This will create the best “cure” of the part which means the plastic powder has fully fused with no air bubbles trapped inside of the wall section. This will also produce the greatest impact strength of the part. As noted earlier, it is not the intent of this paper to discuss the rotational molding process in detail. The paper is focused on mold build rather than the molding process. It was determined that the optimal internal mold temperature would be between 220 and 240 degrees C (428 – 464 F) for 10 minutes. [9] This proved to be an acceptable processing parameter given the part quality that was achieved. VIII PART QUALITY One of the biggest concerns about this project was material shrinkage. It was assumed that plaster, aluminum and HDPE all would shrink resulting in a significant change in size from the original wooden pattern to the completed HDPE part. Figures 31 & 32 Page 10PDF Image | 12 mil Reinforced Polyethylene
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