Sustainable Solar Plastic Molding

MissionLightManufacturing transforms rotational molding

into a sustainable powerhouse.

We harness thermal energy from the sun to mold plastic – with zero energy costs, zero greenhouse

gases. We do this with innovative technology thatcosts less than the traditional alternative.

View the introductory video [ click here ]

SummaryMost large plastic objects are rotationally molded – things like water tanks, kayaks, toys, and shipping cases. Over 3.6 billion pounds of plastic are rotomolded each year, which burns over 18 trillion BTUs of fossil fuels and emits more than 2 billion lbs of greenhouse gasses.

LightManufacturing's Solar Rotational Molding (SRM) process uses thermal energy from the sun focused by simple sun–tracking reflectors – 'heliostats' – to heat the rotational mold.  The heat is used directly, so there's no need for expensive and inefficient photovoltaic panels.  

We move the heat source rather than moving the heavy molds as is done in the traditional process. This 'target-ability' allows for significant simplification of the molding hardware, and lower capital costs.  The result is unique – a solar process that is both cheaper to operate AND cheaper to purchase than the standard approach.

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ProblemEach Year, Rotational MoldingUses > 18 Trillion BTUs of Fossil FuelGenerates > 2 Billion Lbs of Greenhouse Gasses

Rotational Molding Is...Capital Intensive (e.g. $300K–$1M purchase) Land Intensive (metal building, concrete pad) Impacted by increasing energy costsLocked out of new markets due to high entry costs, grid-tie requirement.

Technology

Armatures Heat Control Software Heliostats

Inexpensive electric

armatures turn molds in the solar heat

beam

Thermal containment / molding-shell

design

Armature positioning,

process control system, site productivity

analysis

Computer controlled

mirrors track the sun, and deliver heat to the mold

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Minimal Site Impact

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No grid-tied needed

Uses Existing Tooling / Resins

Example Deployment

Finished Parts

Take-away

• SRM offers Significant Cost Savings• Locate Factories close to Markets - reduced transport costs• Virgin resin or recycled• Same temperature ranges as gas ovens• Potential faster cycle time due to radiative heating vs convective heating• Expands rotomolding’s global potential