Comparing Rotomoulding to Other Plastic Moulding Techniques

In the realm of manufacturing, the creation of plastic products can be achieved through various moulding techniques, each with its unique processes, benefits, and applications. Among these, Rotomoulding stands out for its versatility and cost-effectiveness, particularly in producing large, hollow items. This article compares rotomoulding to other prevalent plastic moulding techniques, highlighting their differences, advantages, and ideal use cases.

Understanding Rotomoulding

Rotational moulding, commonly referred to as rotomoulding, involves a heated hollow mould which is filled with a charge or shot weight of material. It is then slowly rotated (usually around two perpendicular axes), causing the softened material to disperse and stick to the walls of the mould. In order to maintain even thickness throughout the part, the mould continues to rotate at all times during the heating phase and to avoid sagging or deformation also during the cooling phase.

Advantages of Rotomoulding

  • Design Flexibility: Rotomoulding allows for complex shapes and designs with consistent wall thickness, undercuts, and intricate contours without compromising the structural integrity of the product.
  • Cost-Effective for Small Runs: The low cost of mould fabrication makes rotomoulding particularly cost-effective for small production runs and for large, hollow products.
  • Durability: Products manufactured through this process are more resistant to stress-cracking, corrosion, and impacts, making them ideal for a wide range of applications.

How Does It Compare?

Injection Moulding

Injection moulding involves injecting molten plastic into a mould under high pressure. It’s suitable for mass-producing products with highly detailed geometries. Unlike rotomoulding, injection moulding can achieve faster cycle times and produce items with more intricate details. However, it requires more significant initial investments in tooling, making it less cost-effective for small production runs.

Blow Moulding

Blow moulding is predominantly used for making hollow plastic bottles and containers. The process involves inflating heated plastic into a mould cavity. While blow moulding shares similarities with rotomoulding in producing hollow objects, rotomoulding offers more shape versatility and produces products with more uniform wall thicknesses.


Thermoforming shapes plastic by heating a sheet of plastic material and then forming it over a mould. This method is excellent for large panels and relatively shallow products. Compared to rotomoulding, thermoforming is limited in the complexity of shapes it can produce and tends to have a less uniform wall thickness.

Ideal Use Cases for Rotomoulding

Rotomoulding is particularly advantageous for creating large, hollow, or concave items such as tanks, kayaks, and playground equipment. It’s also a preferred method when product durability is a priority or when the production volume does not justify the high mould costs associated with injection moulding.


Choosing the right plastic moulding technique depends on the product’s design, application, volume, and budget constraints. Rotomoulding stands out for its versatility and cost-efficiency in specific scenarios, particularly when compared to other moulding methods like injection moulding, blow moulding, and thermoforming. By understanding the strengths and limitations of each technique, manufacturers can select the most appropriate process for their product, ensuring quality, efficiency, and economic viability.

About Alex

Alex Wilson: Alex, a former tech industry executive, provides in-depth analysis of the tech industry, startup ecosystem, and venture capital.
View all posts by Alex →