The ARICON Kunststoffwerk GmbH

We produce high quality plastic parts in the rotational molding process. In this production process we are able to produce every plastic part with a volume range of 0,1 up to 40.000 liter with low form costs. We are able to realize geometrical specialties such as a complex forming with re-entrant angles, several openings, integrated connections and metal inserts directly in your rotation form. Since its founding, ARICON is the specialist for chemical resistant, seamless hollow plastic parts, plastic container and collecting trays made of polyethylene. The plastic container for liquids and bulk goods as well as the collecting trays and container are made of high quality polyethylene powder in the thermoplastic rotational process. Additionally we also produce customer formed parts made of a variety of materials in the rotational molding process. We accompany you through the whole process of your plastic part. From the first idea and a specific consulting over the construction and development of the design, material and geometrical specialties to the series production and fitting of your plastic part. Contact us! Our experienced team consults you in a first conversation and accompanies you through the production process. We respond to your wishes and we rise to every challenge.

Our possibilities

We realize plastic parts in a thermoplastic rotational molding process. Our experienced team accompanies you from your first idea over the construction to the finished series. We support you with your product development with prototypes and a variety of different individual possibilities of modification. Additionally our CNC-machining center is available for additional milling works to optimize your plastic part.

The rotational process

During the heating of the rotational molding process the plastic powder is rotated biaxial. This means that the arm on which the plate with the form is mounted is rotating as well as the plate itself is rotating. Through this motion the melting plastic powder spreads equally on the insides of the form. The wall thickness can be varied by using different amounts of powder. In this production process the seamless plastic parts can be realized in one part and without stretched parts. During the whole production process only the gravitation is used, which is why this process is also called a pressureless process. The process is divided into 4 production stages. First the form is filled with the powder. After the form is closed the arm is moving into the oven. There the plastic powder is melting and spreads evenly on the insides of the form. Subsequently the arm moves into the cooling chamber where the melted plastic powder is cooled down to the extraction temperature. In order to prevent cords the form is also rotating throughout this phase. As soon as the melted powder is cooled down to the extraction temperature, the plastic part can be extracted from the form and can be further worked on.

Process advantages

Our process offers many advantages concerning the forming and possibilities for the design of your plastic part. We can produce large dimensioned hollow plastic parts seamlessly with openings or as well completely closed. Even complex geometries form no obstacle, thus we are also available to realize complex forms such as re-entrant angles. Further we can build in metal inserts and lead-throughs in the roto mold process. As well there is a great variety in materials and additives as well as colors and pigments to design your plastic part individually and to realize the wished and required characteristics. With a pressureless production process we are able to realize almost every wall thickness with an even spreading and without stretching in radius areas.

Inserts & mountings

In the rotational production process there is the possibility to realize a variety of inserts and mountings adjusted to your application. For example those can be made of metal in form of metal threads or as well metal inserts. Additionally we can realize plastic female and male threads as well as plastic stampings. Furthermore we are able to produce seal areas directly in the process. Thus the additional milling of seal areas is avoided. Additionally we can realize crane eyes and cable fixations in your plastic part in order to make those transportable and to lead the cable secured and fixated along your plastic part.

Types

In the thermoplastic rotational process there are different possibilities to effect the optimal characteristics adapted to your application. In the rotational molding process single walled as well as doubled walled parts can be produced. Thereby there is also the possibility to build layers in form of two or three times multilayers in order to combine different characteristics. Thus a plastic part can be realized in two colors with different ones on the inside and outside. Additionally we are able to build an isolating layer through foaming. Furthermore we can realize ribbings and holds in your plastic part. Additionally we also offer the possibility of integrated lids.

Metal & plastic combinations

Through a combination of the two materials metal and plastic we are able to combine the strengths of both. Through that different characteristics may be linked such as the electro conductivity of metals and the electrical insulation property of plastics. Those connections can be realized directly in the production process. Thereby eventual weaknesses for example leakages, which may occur after a period of time, can be directly excluded. In our roto mold Process we are able to implement those combinations through a high flexibility. Those are implemented in our own production but especially in customer formed parts. Thus the dosing tanks of the series FD-A, FD-C and BD-A have sintered in nuts in the ground area and the doing tanks of the series FD-G and FD-I have nuts on the mounting area for the direct mounting of for example stirrers and pumps.

Material selection

Fundamentally a variety of thermoplastic plastics can be used in the roto mold process. The used material is depending on the application of the formed part and considers next to the temperature resistance and the chemical resistance mechanical characteristics.

Polyethylene - PE

The most used material in the roto mold process is polyethylene. The polyethylene is thereby divided into different densities: PE-LD 0,915 - 0,935 g/cm3 PE-HD 0,940 - 0,970 g/cm3 PE-LLD 0,870 - 0,940 g/cm3 Depending on the application and the required product the densities and melt flow indices (MFIs) of the materials in the roto mold process may vary. For example materials with a high density are used for the production of large containers whereas for design parts and lighting parts materials with a high melting indices are used. Thereby labeling and scales can be displayed detailed which is rather difficult when using materials with fairly low MFIs. Polyethylene further has the great advantage of a high machining time and is resistant concerning rather aggressive chemicals. Furthermore polyethylene has a great usage temperature range from -20 °C up to +60 °C. Polyethylene is often used for lamps as well as kayaks and boats. However polyethylene is also used for the storage of chemicals and bulk goods.

Cross linked polyethylene - X-PE

Through the mixing of different additives (mostly with a peroxide basis) a chemical process is happening during the production process, which changes the characteristics of the material. Until the activation temperature is reached the polyethylene has a high MFI and has thereby rather bad mechanical characteristics. Through a reaching of the activating temperature a chemical linking of the material happens. This results in a great impact and temperature resistance. The high melt flow index of the material at the beginning of the process allows the designing of complex contours. Because some additives are aggressive to steel we recommend only the use of aluminum forms. Due to good static material characteristics the wall thicknesses of the form can be reduced without reducing the static characteristics which favors the usage of this material for weight critical parts.

Polypropylene - PP

Next to polyethylene also polypropylene can be used in the rotational molding process. Polypropylene is a thermoplast which has a better thermal resistance than polyethylene. The capacity ranges from +100 °C to -10 °C although the impact resistance radically reduces below 0 °C. The density lies between 0,895 g/cm3 and 0,92 g/cm3 and has thereby a lower density than polyethylene. The application area is similar to the one for polyethylene, although depending on the application a higher temperature resistance is valued. However this effects higher costs for the polypropylene part due to higher machining temperatures and longer cycles.

Polyvinylidene fluoride - PVDF

PVDF is valued because of its great thermal and chemical resistance and is often used for special applications where the often used materials polyethylene and polypropylene have reached their limits. The temperature resistances goes up to 140 °C and offers thereby new possibilities to replace metals with plastic. Additionally the material has the great advantage of the classification in the flammability class V0 (3mm UL94). The high melting temperatures increase the cycles and machining temperatures and thereby have higher requirements for the fabricator. Additionally the raw material costs are way higher than the ones for polyethylene and polypropylene. The material has a fairly higher density than the other materials with 1,71 g/cm3 to 1,78 g/cm3. Due to a modern machinery the ARICON Kunststoffwerk GmbH is able to machine those materials with high requirements.

Polyamide - PA

There is also the possibility to use polyamide in the roto mold process. Because of its great chemical resistance concerning organic solvents it can be used to build a barrier for hydrocarbons. This often takes place in the multilayer production. The high stiffness and varnishability are further advantages for the use in as design parts. A further advantage of polyamide is the temperature range up to 140 °C. By creating a multi-layer structure it is possible to combine the positive characteristics of polyethylene and polyamide for example. Because polyamide has the characteristic to take in water (hydroscopic) it is necessary to do a drying process before using the material. Otherwise there would be optically disruptions in the material surface or worse brittleness which could destroy the plastic part. The density of polyamide lays depending on the crystallite and type (PA6 to PA12) between 1,01 g/cm3 and 1,235 g/cm3.

Polycarbonate - PC

Polycarbonates have an exceptional position in the rotational molding area, because they are only used for design and special constructions. The production is not easy because of a low or almost not existing shrinkage. The material has a low impact and chemical resistance. But it has a glass like light transmission and is thereby fairly transparent and especially interesting for design applications. Through an admixture of pigments different effects for lighting corpuses and design objects can be done. Polycarbonate has also the classification V0 according to the UL94. Formed parts made of polycarbonate can be used at temperatures over 120 °C, which increases the requirements during the production process. Often polycarbonates are used for the production of CDs, DVDs, Blu-rays, glasses and helmet visors.

Foamed material

By the using of modified polyethylene, which were offset with a foaming agent, the plastic can foam during the process. While the material is heated in the rotational molding process the foaming gent is activated. This brings the polyethylene to foam due to which the polyethylene expands four to six times. The thereby developed structures have many air bubbles and have the advantage to be very resistant due to a high volume although they are lightweight. The developed air bubbles go through the whole material and are not closed but open porous. Because of this negative characteristic the foaming material is often used in combination with conventional materials by using the multi-layer structure. The application areas are beneath others boats for a high stability and a low weight, cooling boxes for a reduced warmth transfer due to an isolating layer and design objects with sound absorbing characteristics. The density of the material lays between 0,15 g/cm3 and 0,31 g/cm3.

Electro conductive material

The admixture of soot reduces the surface resistance of the plastics and makes those conductive to a certain level up to 2,5 x 10 ^-5 Ω/m². After the soot is added to the raw material the material is extruded and made to powder. This guarantees a good and constant integration of the soot pigments in the raw material, which is why this can be also used in the food industry. The high deflecting characteristics allow the containers and special formed parts to be used EX protected areas. Because of the soot the plastic is colored black and not transparent. The material is often used in EX protected areas, in which a potential charge can lead to an electric arc and an explosion. Applications in the food area such as alcohol, but also bulk goods in which plastic granulates are mixed or added require the use of electro conductive material. In those cases the constant friction can lead to a potential charge which may discharge through a person.

Flame-retarding material

Polyethylene and polypropylene can be made to flame-retarding material according to the UL94 through different additives. Through this admixture of additives the chemical as well as the impact resistance fairly reduces. However therefore the materials reach according to the UL94 the classification V0 or also V2 and can be used for example for the production of design products such as lighting corpuses, furniture and bins. By using this material it is also possible to fulfill the requirements for the assembly of these products in public buildings. The material is in transparent as well as every other demanded color. The density of the material lays between 1,029 g/cm3 (PE) and 1,1 g/cm3 (PP).

Multi-layer production

As mentioned above in the rotational molding process there is the possibility of a multi-layer production. This may have the following reasons: Design Through the use of two different colors the outside contour of a formed part for example a vase can be white while the inside is in a deep red. This has the advantage that an additional varnishing of the surface is not necessary and due to a throughout colored material light scratches on the surface can be laminated. Improvement of chemical characteristics The usage of a material mixture can have the improvement of chemical characteristics as result. As already mentioned in the paragraph about polyamide, the outside may be made of polyamide while the inside is supported by polyethylene. Thus the formed part has the resulting stability of a polyethylene part and the positive chemical characteristics concerning hydrocarbons for the usage as a motorcycle tank. Improvement of stability With the help of foaming material hollow corpuses can be produced in the rotational molding process with a high stability, but without the weight of a full material part. The outside of the part can be made of PP or PE and offers a closed surface. Then a rather thick but light layer made of foaming PE is added. This increases the stability of the formed part without raising the weight of the part drastically. Because the inside is not applicable for every application due to the open porous layer, often there is added a triple layer made of full material after the foaming. The result is a robust and light formed part as for example kayaks or as well formed parts with isolating characteristics such as cooling boxes.

Prototypes

Our strength is the competent, specific and extensive consulting for the implementation of your developing project. On demand we provide samples and prototypes before the real production. Thus you have the possibility before the real production to use the samples for first tests and to optimize them if necessary. This saves you a lot of time and costs. Furthermore you have a first impression of your plastic formed part. In the building of samples and prototypes a cost optimized and accurate implementation of the customer demands is important. We offer you everything from the idea to the implementation of your formed part. Through the support of our experienced team your requirements will be developed creative and function oriented. By using CAD programs the prototype can be configured accurately and if needed analyzed with a FEM simulation. The finite element method (FEM) examines the plastic part according to stability requirements and weaknesses. We produce the prototypes in our own prototype manufacturing workshop. Increased requirements concerning dimensional accuracy of the formed part accurate measurements and documentations are always possible. Our strength is the goal oriented implementation and individual solution of the requirements. If you have an idea, a drawing or already finished 3D data, we support you through the product developing and with a quick implementation of models and prototypes. We provide you in a short amount of time with samples and small series. Contact us and get to know more about our service.

Surface engineering

Surface engineering for the refinement of your products. Every surface is special and has to be adapted to your wishes individually. We support you from your first idea to the finished product. Next to the technical function and the required usage characteristics as well design, optic and haptic play a great role in the production and developing of our plastic parts. Our surface engineering has production techniques to change the defined surface characteristics of your plastic part. In the area of surface engineering our experienced personnel supports you with well-grounded know how in the area of surface engineering. For every application we find the right surface. In a first meeting we discuss and mark the technical and formal details on unstructured plastic parts. Gravure bevels and transitions can be determined. Previously CAD data can be examined and reality analyses for the implementation can be done. Our first priority is to fulfill your requirements concerning haptic, optic and acoustic as well as your requirements concerning the function specifications. We offer our customers the possibility to refine the forms with the newest 3D laser gravure, the laser etching gravure as well as the classical etching gravure. In order to realize high quality and cost optimized surfaces we can polish, sandblast your form or cover it with chrome. Due to our manifold possibilities of surface engineering we can make the surface even, rough, dull, scratch insensitive, polished or structured and for example create a wood, stone or leather optic. The 3D laser gravure is realized through modern and high capacity technologies. Thus we are able to offer you almost no limited design possibilities for innovative and individual surfaces. Through an axis fiber laser the gravure is brought in all dimensions directly into the form of the tools. A successive building of the gravure topography is done in separate steps with different layer strengths. The amount of layers and steps decides the depth and three dimensionality of the gravure. The laser etching gravure combines classical and modern technologies. The design is transferred to the with a protection lack covered tool through laser. A gravure picture is cleared for the subsequent etching process through a laser on the lack. The finale gravure is done in an acid bath which removes the material surface on the freed areas through the laser. After a rinsing of the surface the process is finished. Depending on the wished gravure picture the process steps can be repeated for several times. Next to single layer gravures we can also offer you multi-layer gravures. Different acids and transfer mediums are used depending on the designed elaboration and technical requirements for the etching gravure. The transfer of the design is done through the reaming of classical wax print or modern milt-layer coats. The latter are transparent and easily expansive and enable a skilled graver the best possible adaption to the form of the tool. We have an extensive assortment of surfaces with allows us to cover the manifold applications. Provision of samples with different structured samples can be done if required in our production. We also develop especial verified surfaces if your desired surface is not already there. For every application we find the optimal solution. Contact us! Our experienced team looks forward to you.

Polished surfaces

On demand we can offer your plastic formed parts with a polished surface. Therefore the tools have to be polished. Through an additional chrome coating after the polish process the polish degree can be further optimized.

Dull surfaces

We can also realize fine dull surfaces by sand blasting the tool through compressed air. Thereby we are able to individually determine the degree of roughness and produce fine or rough dulled surfaces.

3D surface structure

Because of our laser gravure we have almost no limited design possibilities for innovative and individual 3D surfaces such as a carbon optic which is directly implemented into the tool. However we can also put those into the product through a subsequent etching process. The amount of layers decides about the three dimensionality and depth of the gravure. This lays mostly between 5 and 70 different layers. Often the 3D surface structures are used in the interior of cars where those can be found in form of different textures and leather imitations.

Surface structure

Individual structures can be realized in your plastic formed part by providing the tool with an etching gravure. The implementation of the designs such as a leather structure, happens through a reaming of classical wax print or modern multi-layer coatings. There are almost no limited possibilities concerning the design and structuring of surfaces. The inspiration can come from everywhere and take on every form.

Distinct surfaces

As well deep and lifelike surface structures such as wood or stone Structures can be realized directly in your plastic formed part. In order to do so deep structures have to be cut into the tool through modern CNC machining centers.

Labeling

We can design your plastic part individually also through labeling. We can position special labels in your tool which go into a firm connection with the plastic formed part during the production process. The subsequent fixing of labels on your formed part is possible. In order to individualize your plastic parts we can realize logos, lettering, trademarks or individual texts on your plastic part on every part in a sublime form. But also symbols that are extended into the formed part such as writings, logos, trademarks or individual texts can be realized on every part on your plastic formed part by cutting it into the tool which can be on demand as well in form of a changing application.