Custom Rotational Molded Solutions
Do More with Rotomolding
Simplify Complex Parts with Custom Rotational Molding
Develop durable, high-quality parts while simplifying production. Elkhart Plastics partners with OEM engineering teams to design and manufacture custom rotomolded components optimized for strength, reliability, and long service life.
Through collaborative design, precision tooling, and scalable manufacturing, we help OEMs replace complex assemblies with single-piece rotomolded parts that reduce costs, improve durability, and streamline production.
Advantages of Rotomolding:
- Optimize an existing plastic product or part for better, less expensive, or faster manufacturing
- Convert to affordable plastic from an expensive material like metal, fiberglass, or wood
- Eliminate assembly headaches by making a complex, multipiece product or part in a single mold
- Bring a custom idea to life AND optimize it for efficient manufacturing
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.
From large, heavy-duty components to intricate, multi-functional designs, Elkhart Plastics manufactures custom parts for virtually any application.
Why Choose rotational molding?
Our Custom Rotomolded Solutions Improve Part Performance While Reducing Total Manufacturing Cost
Long-Term Cost Savings
Lower Production, Tooling & Material Costs
Rotational molding reduces total production costs by consolidating multiple components into a single molded part, eliminating the need for welding, fastening, or secondary assembly.
Low operating pressure allows for more affordable tooling materials, such as cast aluminum or fabricated steel, lowering upfront investment. Additionally, the durability of molds supports cost-effective production across both low and high volumes.
By simplifying manufacturing and reducing labor requirements, rotomolding helps deliver long-term cost savings.
Higher Quality Parts
Stronger, Seamless Parts with Uniform Wall Thickness
The bi-axial rotation process ensures the mold is evenly coated, producing uniform wall thickness throughout the part. This uniformity can be maintained within ±10 percent, something many other molding methods struggle to achieve.
This consistency improves structural integrity and eliminates weak points, while one-piece molded construction removes seams, welds, and joints that can fail over time. Parts can also be engineered with reinforced corners, thicker stress areas, and double-wall construction, ensuring durable products that are designed for demanding environments.
Reduce Waste and Environmental Impact
Sustainable Manufacturing Solution
Rotational molding is an efficient process that uses only the material required to form the part, generating minimal scrap during production.
Any excess material can often be reclaimed and reused, and the process does not require hazardous byproducts or emissions. This results in a cleaner manufacturing method that supports environmental sustainability while reducing material costs.
Simplify Complex Parts
Greater Design Flexibility
Rotomolded products can be engineered to meet a wide range of performance requirements, including FDA-compliant applications, chemical resistance, flame retardancy, and durability in harsh outdoor environments.
Rotational molding offers exceptional design flexibility, enabling the creation of complex shapes, hollow parts, and integrated features that would be difficult or costly to achieve with other processes. Products can incorporate:
- Molded-in inserts and integrated components
- Reinforcing ribs, undercuts, and contours
- Multi-wall or double-wall constructions
- Openings and intricate geometries
This flexibility allows for part consolidation, improved functionality, and greater design freedom, whether the application is simple or highly engineered.
High-Quality Finishes
Molded-In Textures, Graphics & Branding
The rotational molding process enables high-quality surface finishes with molded-in textures, logos, symbols, and detailed branding elements, eliminating the need for secondary finishing.
By integrating these features directly into the part, you can improve durability, enhance product appearance, and reduce additional labor and production costs.
Shorter Lead Times
Faster Production & Delivery
Compared to other molding methods, rotomolding tooling can be produced more quickly due to its simpler, low-pressure mold requirements. This allows manufacturers to move from design to production faster, making it easier to prototype, test, and scale new products efficiently.
Because parts can often be produced without secondary operations, manufacturers can accelerate production schedules, respond quickly to demand, and bring products to market faster.
With in-house mold building and manufacturing capabilities, Elkhart Plastics further streamlines development, reducing delays and helping move projects from concept to production more efficiently.
Long-Lasting Performance
Dimensionally Stable, Low-Stress Parts
The absence of high-pressure molding results in parts with low internal stress, reducing the risk of warping, cracking, or deformation over time.
Combined with uniform wall thickness, this produces dimensionally stable, long-lasting components that maintain performance even in challenging environments.
Lower Production, Tooling & Material Costs 
Stronger, Seamless Parts with Uniform Wall Thickness 
Sustainable Manufacturing Solution 
Greater Design Flexibility 
Molded-In Textures, Graphics & Branding 
Faster Production & Delivery 
Dimensionally Stable, Low-Stress Parts End-to-End Support – Elkhart Plastics supports every phase of your project, from initial design and material selection to tooling, manufacturing, and final delivery.Learn more about our capabilities
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.
