Seamless parts without welded joints – zero leakage points
Large parts up to 4 × 2 m produced locally
Low tooling costs – steel or aluminum tools
TECHNOLOGY
Powder, heat and biaxial rotation
Powdered plastic is placed in a closed tool that is heated and rotated around two axes simultaneously (biaxially). The plastic gradually melts and spreads evenly along the tool walls, giving the part a stress-free structure with uniform wall thickness across the entire geometry. The result is large, hollow, impact-resistant parts in a single operation – ideal for tanks, fenders, buoyancy elements, complex ducts and special products that can withstand rough use over time. Metal inserts, threaded bushings and graphics can be integrated directly into the cycle, eliminating rework.
CAPACITY
What we can deliver
MAX DIMENSION
Up to 4 × 2 m
VOLUME PER PART
Up to several thousand liters
WALL THICKNESS
2 – 12 mm, uniform
SERIES SIZE
30 – 5,000 pcs
PE (LLDPE / HDPE)
Impact-resistant, chemical-resistant and UV-stable – standard for rotational molding.
Cross-linked PE (XLPE)
Improved chemical resistance and temperature performance.
Flame retardant PP
Higher temperature resistance and stiffness – for fire-resistance requirements.
Conductive qualities
ESD-safe parts for electronics and explosive environments.
Foam core and barrier layer
Multi-layer tools provide integrated insulation or chemical barrier.
Recycled and food-grade
Sustainable alternatives and qualities for food and farming.
AREAS OF USE
Plexx has delivered rotationally molded elements to:
Tanks and containers
Water, chemical and fuel tanks for industry, aquaculture and transport – up to several thousand liters.
Farming and marine
Fenders, buoyancy elements and robust plastic parts that withstand saltwater, UV and physical stress over long periods.
Complex channels and covers
Geometrically demanding ventilation and air ducts in one seamless part – without welds and without leak points.
WHEN TO USE ROTATIONAL MOLDING
Choose this method when…
The part is hollow and large – typically from a few tens of liters up to 4 × 2 m
You need a seamless shell without welds or leak points
The series is from 30 to 5,000 units.
Impact resistance, UV resistance and longevity are critical
You want metal inserts, threads or graphics integrated into the cycle
Tool investment must be kept low
BENEFITS
Why choose Rotational Casting?
The method combines low tooling costs with the ability to create large, seamless parts in demanding environments.
Completely seamless
No weld seams means zero leak points and consistent strength across the entire part.
Low tooling costs
Tools in steel or aluminum
Large dimensions
Parts up to 4 × 2 m are produced locally.
Stress-free structure
Low pressure in the process gives uniform wall thickness and minimal internal stress.
Material flexibility
UV-stable, flame retardant, conductive, foamed and recycled qualities.
Integrated details
Metal inserts, threaded bushings and graphics are cast into the cycle itself.
FAQ
Frequently asked questions about rotational molding
We produce parts up to approximately 4 × 2 meters and volumes of several thousand liters — in one seamless part.
Typically 30 to 5,000 units, but larger series can also be delivered if needed.
Mainly polyethylene (LLDPE/HDPE), cross-linked PE (XLPE), flame retardant PP and conductive grades. We can also run multi-layer tools with foam core or chemical barrier.
Yes. Threaded bushings, metal inserts and graphics fuse with the plastic in the cycle — eliminating assembly and rework.
Steel or aluminum tools are typically a fraction of an injection molding tool — making the method attractive even for moderate volumes.
Biaxial rotation provides uniform wall thickness, typically 3–12 mm, across the entire geometry — even in corners and complex sections.
Yes — UV-stable, impact-resistant and chemical-resistant PE grades make the method ideal for hollow elements, buoyancy elements and tanks that are exposed to harsh environments.