Dino Rentos Studios's artist use rotocasting to create highly detailed castings of your custom prop manufacturing. Rotocasting allows us to replicate over and over all the detail of your prop or display piece. Each piece is hand casted with the assistance of a rotocasting machine.
How does this process work?
1) First we start off by creating a master sculpture of your prop. This can be 3D printed, hand sculpted in clay or an original model.
2) We create a master mold from the sculpture. By layering silicone rubber and hard plastics a mold is hand made of your prop/product. This is also known as the tool.
3) The mold is placed in the rotocasting machine and filled with plastic resins. By turning on the rotocaster the mold is spun slowly in multiple axis. This motion slowly coats the inside of the mold with the resin building a hollow plastic part over a period of 15 mins. Time is given to allow the plastics to cool.
4) The part is removed from the master mold, cleaned and prepped for painting. This process is repeated.
More information and videos will be added shortly.
In 1855 R. Peters of Britain documented the first use of biaxial rotation and heat. This rotational molding process was used to create metal artillery shells and other hollow vessels. The main purpose of using rotational molding was to create consistency in wall thickness and density. In 1905 in the United States F.A. Voelke used this method for the hollowing of wax objects. This led to G.S. Baker's and G.W. Perks's process of making hollow chocolate eggs in 1910. Rotational molding developed further and R.J. Powell used this process for molding plaster of Paris in the 1920s. These early methods using different materials directed the advancements in the way rotational molding is used today with plastics.
Plastics were introduced to the rotational molding process in the early 1950s. One of the first applications was to manufacture doll heads. The machinery was made of an E Blue box-oven machine, inspired by a General Motors rear axle, powered by an external electric motor and heated by floor-mounted gas burners. The mold was made out of electroformed nickel-copper, and the plastic was a liquid PVC plastisol. The cooling method consisted of placing the mold into cold water. This process of rotational molding led to the creation of other plastic toys. As demand and popularity of this process increased, it was used to create other products such as road cones, marine buoys, and car armrests. This popularity led to the development of larger machinery. A new system of heating was also created, going from the original direct gas jets to the current indirect high velocity air system. In Europe during the 1960s the Engel process was developed. This allowed the creation of large hollow containers to be created in low-density polyethylene. The cooling method consisted of turning off the burners and allowing the plastic to harden while still rocking in the mold.