How are kayaks rotomolded?

1. Preparation of Raw Material:

- Polyethylene or other thermoplastic material is used in pellet form.

- The pellets are dried to remove moisture before processing to prevent porosity and defects in the final product.

2. Mold Preparation:

- A two-part, hollow mold is used for rotomolding kayaks.

- The mold is preheated to a specific temperature appropriate for the material being used.

3. Loading the Mold:

- The dried plastic pellets are loaded into one half of the mold, which then closes securely around the pellets.

4. Rotational Heating and Cooling:

- The mold is placed in an oven or a heating chamber, where it slowly rotates on multiple axes.

- This rotating action ensures uniform heating and melting of the plastic material inside the mold.

- The temperature is controlled to prevent scorching or burning of the material.

5. Cooling:

- After the plastic melts and fills the mold cavity, the mold is removed from the heating chamber and allowed to cool.

- This cooling process can be done by air, water, or other cooling agents.

6. Mold Opening and Unmolding:

- Once the kayak shell has cooled and hardened, the mold opens, and the finished kayak is removed.

- Excess material, known as "flash," is trimmed away to create a smooth and clean finish.

7. Quality Inspection:

- The kayak is visually inspected for any defects, such as voids, porosity, or cracks.

- Additional tests, like pressure testing for watertight integrity, are sometimes performed.

8. Finishing:

- Depending on the specific design and requirement, additional finishing steps may be performed.

- These may include adding features like seating, footrests, hatches, carrying handles, and attachment points for accessories.

9. Quality Control and Packaging:

- The completed kayak undergoes final quality control checks to ensure it meets the desired standards.

- After inspection, the kayak is packaged appropriately for storage, transportation, and delivery.

Rotomolded kayaks are known for their durability, versatility, and ability to withstand various environmental conditions. They are commonly used for recreational activities, fishing, and water sports due to their stability and ease of handling.