Our Rotomolding Capabilities
Our Capabilities
A Single Source Partner for Custom Rotational Molding
From design collaboration and mold development to manufacturing, assembly, and logistics, Elkhart Plastics brings every stage of the rotomolding process together under one roof. This integrated approach helps manufacturers simplify production, reduce complexity, and bring high-quality products to market faster.
When you partner with Elkhart Plastics, we become an extension of your team. Our design and engineering experts work closely with you to understand your requirements and develop innovative solutions that ensure your project is completed efficiently, reliably, and to the highest quality standards.
Custom Parts at Any Scale
Create Custom Parts That Fit Your Design, Performance, and Production Needs
Scale Without Limits
Rotational molding supports a wide range of product sizes and applications. By adjusting materials, wall thickness, and finishes, gain the flexibility to produce durable parts tailored to your unique specifications.
From Simple to Complex
Rotational molding can often eliminate secondary assembly by producing single-piece components that improve strength while reducing costs.
Rugged or Refined
From rugged components built to withstand harsh conditions to products with refined surfaces and molded-in colors, rotational molding is engineered for performance and aesthetics.
Our Process
From Design to Delivery
Developing high-quality rotomolded products requires collaboration across engineering, tooling, manufacturing, and logistics. Elkhart Plastics works closely with OEM teams to guide projects from initial concept through production and final delivery.
Engineering & Design
Develop a Better Performing Product
Reduce production costs while improving part performance. Our engineering team works directly with your team to evaluate performance requirements, manufacturing considerations, and material options to ensure your product is designed for a durable long life. We can help you:
- Optimize designs to reduce costs
- Select materials based on performance requirements
- Perform structural analysis and wall thickness optimization
- Integrate molded-in features and assemblies
Mold Making
Precision Tooling That Drives Part Quality
High-quality molds are essential to producing consistent rotomolded parts. Our design and engineering team works with customers to determine the best tooling solution based on product size, geometry, surface finish, and production requirements.
Our team supports both in-house mold fabrication and partnerships with specialized mold makers, ensuring each project receives tooling designed for durability, precision, and long-term production performance.
Tooling Types
Different tooling approaches are used depending on part complexity and production needs.
Fabricated Sheet Metal Molds – Often used for large parts with simpler geometries. These molds offer a cost-effective solution and shorter lead times.
Cast Aluminum Molds – The most common tooling option, capable of producing complex shapes and a wide range of surface finishes. This is a great option for products like RV liners or holding tanks.
Billet / CNC Machined Molds – Used for complex designs requiring smooth surfaces and tight tolerances.
Selecting the right tooling approach helps ensure reliable production and consistent part quality.
Manufacturing
Efficient Production Built for Quality, Scale and Consistency
Once design and tooling are complete, Elkhart’s manufacturing process is optimized to produce high-quality rotomolded parts with consistency and efficiency. Our advanced processes deliver durable, seamless parts with uniform wall thickness, reduced material waste, and reliable performance across every production run.
With multiple U.S. manufacturing facilities, we scale production to meet demand while maintaining tight quality control and operational flexibility. Whether supporting low-volume programs or high-volume production, our team ensures efficient lead times, dependable output, and the ability to adapt as your needs evolve.
Quality Systems
Ensure Consistency and Performance
We are committed to providing quality products and services that meet customer, regulatory, environmental requirements, and prevent pollution through teamwork and continuous improvement.
Process Monitoring & Measurement
We conduct numerous visual and mechanical inspections during each step of the process and gladly conduct any special testing your part may require. We surpass plastics solutions providers all over the country with our superior quality-control systems:
- State of the art processes and technologies.
- State of the art visual inspection tools and processes.
- State of the art Measurement Systems, Analysis tools and processes.
- Controls that are customizable to the facility, line, application.
- Automated, digital, and vision systems for leak testing.
- Unsurpassed repeatability, traceability, and reproducibility.
Some of our quality testing processes include:
- Multi-level production part approval process (PPAP)
- FARO Arm coordinate measuring
- Machine cycle validation and documentation
- Geometric Dimensioning and Tolerancing (GD&T)
- Failure Mode and Effects Analysis (FMEA)
- BYK Gardner Color Measurement Systems
Certified Quality Systems
Elkhart Plastics operates under internationally recognized quality and environmental standards to ensure consistent manufacturing performance.
- ISO 9001:2015 certified quality management systems
- ISO 14001:2015 environmental management standards
- Documented production procedures and traceability
These standards support continuous improvement and provide confidence that parts are produced under controlled, repeatable processes.
Secondary Assembly
Production-Ready Components
Streamline production with integrated secondary assembly services. By completing finishing and assembly steps in-house, you’ll receive parts that are closer to final installation or end-use.
Finishing & Machining Operations
After molding, parts can be processed using a variety of finishing techniques to meet functional and dimensional requirements. Our capabilities include:
- CNC routing and trimming
- Drilling and machining openings
- Spin welding or thermal welding of fittings
- Surface finishing
Hardware & Component Integration
As part of our integrated manufacturing solutions, we can install:
- Fittings and threaded inserts
- Valves, sensors, and hardware
- Hinges, handles, and accessories
- Graphics, labeling, or molded-in branding
Assembly, Packaging & Inventory
Save time with parts that are fully assembled and ready for distribution or installation. We offer
- Multi-component product assembly
- Foaming for insulation or structural support
- Inventory staging and control
- Custom packaging and shipment preparation
Shipping & Storage
From Production Through Delivery
By aligning manufacturing schedules with customer supply chains, we help simplify product distribution. Our distribution team supports customers with coordinated storage, inventory management, and shipping solutions that ensure parts are available when and where they are needed.
Engineering & Design 
Mold Making 
Manufacturing 
Quality Systems 
Secondary Assembly 
Shipping & Storage Parts Conversion
Transform Existing Designs Into High-Performing Rotomolded Parts
Through engineering-led design evaluation and rotational molding expertise, Elkhart helps manufacturers convert existing parts into more durable, cost-effective solutions that are easier to produce, assemble and scale.
