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Rotational Molding of Nylon Air Intake Resonator for the Power Generation Industry

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A client in the mobile power generation industry came to Rhino, Inc. for rotational molding of a nylon air intake resonator. The resonator was to be used for regulating air intake for gasoline powered generators. Our team of experts manufactured the mold and the cutting fixtures allowing us to meet the tight tolerance specifications. Multiple kiss-offs and high temperature airflow design were among the special features we achieved with this project.

The completed nylon 12 intake resonator had a 330 shot peen texture applied. The part measured 274 mm long, 79.5 mm high and 200 mm wide. The temperature range for this part was up to 250 degrees F. We worked within tolerances of +/- 1.0 mm. Meticulous testing involved air leak and minimum PSI requirements. Once production and inspection were completed, the product was shipped to the client for final assembly and fit-up. The client was extremely pleased with the final result.

To learn more about this project, or for more information on our other products and services, please contact Rhino, Inc.





Rotational Molding of Nylon Air Intake Resonator - Project Details

Product Description
This Rotational Molded Air Intake Resonator is used for exhaust airflow regulation from gasoline powered generators.

Capabilities Applied/Processes
Rotational-Molding
Tooling Manufacturing
  • Manufacture Mold and Associated Cutting Fixtures
CNC Milling
Secondary Operations
  • Trim Flashing
  • Cut Ends
  • Cut Slots

Equipment Used to Manufacture Part

H-100 Hurricane Shuttle Oven
Hand-trimming tool (remove parting line flashing)
Hand router with 1/8" bit
Cutting Fixtures

Overall Part Dimensions
Length: 274 mm
Width: 200 mm
Height: 79.5 mm

Tightest Tolerances
±1.0 mm

Temperature Range
+250 °F

Material Used
Nylon 12

Component Finish
330 Shot Peen

Color
Black

Special Features
Multiple Kiss-Offs
Designed for Part to Hold Shape During High Temperature/High Airflow

In Process Testing Performed
3 PSI with soapy water
Air Leak Test

Industry for Use
Power Generator

Standards Met
Customer supplied the design work
SolidWorks format

Product Name
Nylon 12 Air Intake Resonator