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Rotocasting: All You Need To Know

Table of Contents

Rotocasting, also known as rotomolding or centrifugal casting, is a sophisticated method for forming thermoplastic resins. This technique involves the molten material solidifying in and conforming to the shape of the inner surface of a heated, rapidly rotating container. This blog will delve into the intricacies of industrial rotocasting, its applications, benefits, and the potential for home-based adaptations.

The Industrial Rotocasting Process

How It Works

In industrial rotocasting, the metal or plastic being cast is propelled toward the mold walls, forming the casting upon hardening. The centrifugal force ensures the material spreads evenly, creating hollow castings with smooth surfaces. This method is widely utilized in industries for producing items such as cast-iron and steel pipes, rings, sleeves, and cowlings.


Rotocasting is a high-temperature, low-pressure manufacturing process that combines heat and bi-axial rotation. This unique plastic molding process is particularly beneficial for creating seamless, stress-free, hollow one-piece items. Typical products include containers, tanks, children’s toys, medical and industrial equipment, and automobile parts.

Proponents of rotational molding highlight its low production cost and vast design possibilities. It stands as a competitive alternative to blow molding, thermoforming, and plastic injection molding. Additionally, it produces minimal waste since the exact amount of plastic required is placed inside the mold.

Detailed Steps of the Rotocasting Process

  1. Filling the Mold: The process begins with filling a hollow mold with a quantity of powder resin (polymer). Polyethylene is commonly used, although other compounds like polypropylene, PVC, and nylons are also viable.
  2. Heating and Rotating: The mold is heated at high temperatures in an oven while bi-axially rotating, ensuring the polymer melts and coats the mold’s interior.
  3. Maintaining Uniformity: To ensure even thickness, the mold continues to rotate throughout the heating and cooling phases, preventing sagging or deformation.

Home Rotocasting: DIY Applications

Bringing Industrial Techniques Home

While industrial rotocasting may seem machine-intensive, the process can be adapted for home use. Home rotocasting, akin to resin casting and industrial rotocasting, involves using a resin-cast part placed in a homemade rotocasting tool. This tool spins the mold, using gravity to make it conform to the walls, creating a hollowed-out part.

Benefits for Makers and Hobbyists

Home rotocasting is especially popular among cosplayers and fandoms due to its efficiency in creating lightweight, hollow parts with minimal material. For a practical demonstration, check out this video on a home rotocasted Iron Man leg.

Jaycon’s Expertise in Rotocasting

Jaycon specializes in transforming product concepts into reality through a comprehensive service line that spans product and electronics design, prototyping, and manufacturing. We leverage our technological expertise across various markets, including consumer electronics and beyond.


Rotocasting offers a versatile and cost-effective solution for manufacturing both industrial and home-based products. Its ability to produce high-quality, seamless items with minimal waste makes it an attractive option for various applications. Whether you’re an industrial design professional or a hobbyist, understanding and utilizing rotocasting can significantly enhance your production capabilities.

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