The product design process starts with the “product design specification” which sets out the aims and objectives of the product design. Once this is finalised a number of concepts will be developed using ProEngineer ,3D CAD software to meet the product design specification. The concepts are then reviewed in 3D and a final design will be agreed and developed into a detailed design. The detailed design then undergoes structural finite element analysis (FEA) where required which will identify any areas that need redesigning to meet the structural requirements. The final design then goes through the Design Review process before final product drawings are developed for sign off.

2. Mould Design & Manufacture

The product design is now further developed into a mould design which is dependent upon the construction of the mould and the machine it is to be mounted on. PD Rotomouldings manufacture moulds in one of three ways depending on size, shape and complexity.

Cast Aluminium Moulds

Mainly used for geometrically complex parts and parts that require specific surface textures and finishes.


Sheetmetal Moulds

The most widely used method of mould manufacture in rotational moulding. Used for both small and large parts with varying degrees of complexity.


CNC Machined Moulds

Typically used for small shallow parts with intricate detail. CNC machined parts are commonly welded into larger sheetmetal moulds. PD Rotomouldings have a broad range of mould building capabilities in a purpose built workshop using state of the art equipment and machines.

PD Rotomouldings have a broad range mould building capabilities in house including - sheet metal moulds, CNC machined moulds and a combination of the two. The moulds are manufacturer in a purpose built workshop using state of the art equipment and machines.

3. Production Samples

The next stage is to produce production samples from the completed mould. During this stage the processing parameters are set and honed to produce a quality part.

4. Product Testing & Verification

This is the last stage in the product development process where the finished production parts are tested against design requirements. It will varies in size and complexity depending on design requirements and normally is laboratory based but can be field based if required.