Custom Molding has become a specialty of Bayhead over the past four decades. With our in house mold-making abilities, we are able to offer quick turn-around along with low prices. Our expertise allows you to make up a specialty part for less then prototype costs usually run. We can run small quantities to help prove out a design, or large production quantities. The rotational molding technique also enables a single mold to run a variety of wall thicknesses for no additional mold costs. Whether you need a specialty tank, custom box, unique housing, large or small container, foam-filled float, durable guard, long-lasting toy or something totally different, we're the people to contact!

Rotational Molding Benefits:

• Low Cost Tooling.
• Low-pressure forming results in stress-free parts.
• Economically produce large, hollow items.
• Vary wall thickness without changing molds.
• Quick turn-around results in short lead times.
• Economical prototyping or production runs.

HOW IT WORKS: A powdered resin (usually polyethylene) is loaded into a mold. The lid is secured and the mold moved into an oven. The mold is rotated on two axes at a low speed, allowing gravity to disperse the resin throughout the mold. As the mold heats, the melting resin adheres to the mold surface, fusing into a solid skin. After the cooking cycle is complete, the mold moves into a cooling chamber, rotating while being cooled with air and/or a water spray. After cooling, the mold is opened and the finished part removed.The mold is now ready to repeat the cycle.

Materials -- Polyethylene in various densities and melts is the main material used. (Low density, Linear low and High density) We also offer conductive, anti-static, flame retardant and cross-linked materials.

We specialize in fabricating sheet metal molds in-house in a wide variety of shapes and sizes.  Intricate shapes are possible with steel, or we can work with our cast aluminum mold manufacturers if the design is very intricate.