Why choose roto molding to make custom plastic speaker enclosure?

Why choose roto molding to make custom plastic speaker enclosure?

Molded plastic enclosure becomes prevailing. From home theater systems, car stereo enclosure to the commercial applications, such as sound reinforcement systems, movie theatre sound systems and recording studios, plastic enclosures dominate audio products these days thanks to the advantages of easy molding and low production cost. Among all thermoplastic forming methods, roto molding is prized for its aptitude for generating plastic formations of uniform quality and precise wall thickness with low tooling costs.

An overview of roto molding

Roto molding, or rotational molding is a manufacturing process that relies on gravity and heat to produce plastic parts with exceptional strength. A measured amount of plastic powder is placed into a predetermined dimensions mold and is rotated in two perpendicular axes as it melts and distributes evenly to the interior surfaces of the mold. The rotation continues during the heating and cooling phases. Once the plastic is stale, it then enters the cooling cycle.  After cooling the rotation is stopped and the finished product is removed from the mold. The end products are hollow, stress-free, lightweight and seamless design with the high tensile strength due to single piece construction.

The cost-effective advantages of roto molding

1.Low tooling cost

As it requires less amount of machine shop labor, tooling costs are relatively low in comparison to injection and blow moulding. For example, injection moulding tools can cost up to 10 times that of a roto tool. Since products created by roto molding have no internal core, it allows for a design change on existing mould without re-fabricating the mould. This offers more flexibility to refine the product over time without extra cost.

2. Eliminate the part assembly

Speaker enclosures have traditionally been made from several individual pieces to form an enclosure of varying dimensions and shapes. Plywood, particle board and chip board are among the standard materials used. While the size of the tools and the processes involved in roto molding allows molding even larger or huge plastic products in a single, seamless piece. With other plastic manufacturing processes such as injection moulding, it has to manufacture product in several pieces, and assemble them afterwards. A substantial amount of labor in assembly time is required to build the a speaker cabinet. So, roto molding eliminates extra fabrication costs.

3.Low production cost

One piece rotomolded speaker enclosures are made in a single molding operation requiring very little labor. Plastic material is merely placed in a mold of predetermined dimensions and the roto molding process begins. Roto molding utilizes all material placed in the mold so that no waste is created.

Design flexibility of roto molding

1. A wide range of customization

Roto molding makes allowances for a wide range of customization, including hole cutouts, minor undercuts, LCD windows, and removable cover panels, product characteristics, product sizes, texture, finish, color, fine surface details, or labeling. Labeling includes logos, graphics or other imprints. In addition to those, threaded insert standoffs can be molded in the interior of the plastic enclosures for mounting of electrical components and PCBs. 

2. Allows for much more complex, asymmetrical shapes.

Complex curves, huge size and intricate shape can be easily created which would be difficult or impossible by other molding methods.

High quality standard of roto molding

1. One-piece construction, no welds or joints free, smooth internal and external surfaces

2 .Roto molded plastic enclosures are watertight and airtight and dust-proof to protect all the inside electronic components and circuitry against corrosion and oxidation.

3. Roto molding process is able to create thicker corners and edges for shock resistance

4. Resin can be tailored made to suit the application by adding the additives for moisture protection, flame retardants, static elimination.  For example, material can be impervious to chemical for outdoor use.

5. Size can be precisely controlled as wall thickness distribution is more uniform

As a custom roto molding manufacturer, Light Venus has wealthy experience in manufacturing high-quality plastic speaker enclosures. For a complete view of our capabilities and services, check out our website, or submit a online request for quote to see how we can serve you!