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Rotational Molding of MDPE Forced Air Housing Shell for the HVAC Industry

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A client in the solar heating industry came to Rhino, Inc. for design assistance and manufacturing of an MDPE forced air housing with an insulating EPS foam core. The housings were to be used in a solar collection forced air heating system. Once we determined performance and functional specifications we began working on mold design and manufacturability specifications. With tooling complete, we moved right into production. Secondary processes involved trimming of parting lines, application of graphics, and inserting/forming the EPS foam core.

The housing exteriors were made of MDPE, and the interior cavity consisted of EPS foam. A 550 shot peen finish was applied to the exterior surface of the part, and a mill finish interior allowing us to provide multiple surface textures for both functionality and aesthetics.

Critical dimensions were identified and executed on the interior cavity of the part to hold dimensional tolerances in proportion with additional components with differing heat expansion coefficients. The final product was 79.5 inches long, 5.25 inches high, 39.5 inches wide and weighed 60 pounds.

Once the housings were complete, Rhino's team performed a full inspection including final unit assembly with client to ensure all aspects of assembly were complete and approved. To learn more about this project, or for more information on our other products and services, please contact Rhino, Inc.





Rotational Molding of MDPE Forced Air Housing Shell - Project Details

Product Description
These Rotational Molded Forced Air Housing Shells are used in solar powered forced air heating systems

Capabilities Applied/Processes
Rotational-Molding
Mold Design
  • Rhino played an intricate roll in designing and manufacturing the mold, which was built by American Roto Tool. (CNC Aluminum)
Secondary Operations
  • Trim Parting Lines
  • Apply Secondary Graphic
  • EPS Foam Core

Equipment Used to Manufacture Part

Ferry 330 Oven
Hand-held trimming tool
Hydraulic Steam Bed (EPS Foam Process)

Overall Part Dimensions
Length: 79.5"
Width: 39.5"
Height: 5.25"

Tightest Tolerances
±.125"

Temperature Range
Ambient to Inconsistent Peaks Reaching 150 °F

Material Used
Exterior Skin: MDPE
Internal Core: EPS Foam

Component Finish
Interior Cavity: Mill Finish
Exterior: 550 Shot Peen

Color
Compounded Tan
Light Gray
Natural

Special Features
EPS foam-filled cavity
  • Must hold dimensional tolerances in proportion w/ additional components comprised of different materials (with differing heat expansion coefficients).

In Process Testing Performed
Post-foam dimensional verification

Estimated Part Weight
Finished part - 60 lbs

Industry for Use
HVAC
Solar

Product Name
Forced Air Housing Shell