Material Choices in Rotomolding: What You Need to Know

Rotational molding, or rotomolding, is a versatile manufacturing process used to create durable, hollow plastic products ranging from children’s toys to large industrial tanks. Unlike other molding techniques, rotomolding offers unique benefits, such as uniform wall thickness, lightweight products, and the ability to form complex shapes without stressing the material. However, the choice of material in the Rotomolding process is crucial and can significantly affect the quality, durability, and cost-effectiveness of the final product. Here’s what you need to know about material choices in rotomolding.

Understanding the Basics of Rotomolding Materials

The most commonly used materials in rotomolding are thermoplastics, especially polyethylene (PE), due to their excellent chemical resistance, durability, and flexibility in processing. However, depending on the application and specific requirements of the product, other materials such as polypropylene (PP), nylon, and polycarbonate can also be used. Each material has its unique properties, advantages, and limitations that should be carefully considered during the design phase of a product.

Polyethylene (PE)

Polyethylene is the most popular material for rotomolding for several reasons. It offers great impact resistance, flexibility, and is highly resistant to chemicals and environmental stress cracking. PE is available in several grades, including low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and high-density polyethylene (HDPE), each offering different characteristics suitable for various applications.

Polypropylene (PP)

Polypropylene is another widely used thermoplastic in rotomolding, known for its excellent chemical resistance and higher temperature tolerance compared to PE. PP is stiffer and has a higher melting point, making it suitable for products that need to withstand higher temperatures or require greater rigidity. However, it is also more prone to cracking under stress, so its use must be carefully considered based on the application’s demands.


Nylon is chosen for its strength, stiffness, and high melting point. It is particularly suitable for parts that require good wear resistance and tensile strength, such as gears and industrial containers. Nylon also has excellent chemical resistance, although it can absorb moisture, which may affect the dimensional stability of the final product.


Polycarbonate is used in rotomolding for products that require high impact strength and clarity. It offers excellent toughness and temperature resistance, making it ideal for creating parts that need to withstand harsh conditions. However, polycarbonate is more expensive than other materials and may require special processing conditions.

Factors to Consider When Choosing a Material

When selecting a material for a rotomolded product, consider the following factors:

  • Application Requirements: The material should meet the physical, chemical, and environmental requirements of the application.
  • Durability: Consider the material’s resistance to impact, chemicals, and environmental stress cracking.
  • Cost-Effectiveness: Some materials are more expensive than others, so consider the cost relative to the performance benefits.
  • Processing Characteristics: Each material behaves differently in the rotomolding process, affecting the ease of manufacturing and the quality of the final product.


The choice of material in the rotomolding process is critical to achieving the desired performance and durability of the final product. By understanding the properties and advantages of different materials, manufacturers can make informed decisions that meet the specific needs of their applications. Whether it’s the impact resistance of polyethylene, the high temperature tolerance of polypropylene, the strength of nylon, or the clarity of polycarbonate, selecting the right material is key to the success of any rotomolded project.