Custom Rotational Molding Quote Request


About Custom Rotomolding

Rotational molding is a manufacturing process that relies on gravity and heat to produce parts with exceptional strength. The finished product is a stress-free, lightweight and seamless design that is very durable.

Plastic powder is placed into a heated hollow mold and is rotated in two perpendicular axes as it melts and disperses evenly around the interior surfaces of the mold. The rotation continues during both the heating and cooling phases. Once the plastic is stable, it then enters the cooling cycle.  After cooling the rotation is stopped and the finished part is removed from the mold.

Advantages of rotational molding include design flexibility, durability, low cost tooling and uniform wall thickness.  A wide range of sizes and shapes can be molded.  Rotomolding also has many options for colors, material selection and textures. Very little material is wasted during the process, and excess material is often re-used, making it economical and environmentally friendly.

Rotomolding tools can be machined, cast or fabricated from materials such as steel, aluminum or stainless steel. Cast and machined molds are best when tight tolerances are needed, or cosmetic finishes are important to the finished product. Cast molds offer a wide range of finishes from wood grain to a mirror finish. Fabricated molds are more economical than cast or machined molds but offer less options for finish.

IRP’s manufacturing and fabrication plants in Decorah, IA are equipped with state-of-the-art Ferry rotomolding machines, CNC router, dedicated foam room and equipment, plasma treater, and full assembly line. We have a wood shop and a full metal-working shop with 50+ years of experience in our expert staff.

Past and current clients include Fortune 500 companies such as Anheuser Busch InBev, MillerCoors, PepsiCo, Gatorade, Coca-Cola, and many more. Our experience in partnering with OEMs and companies from all trades has led us to being recognized as leaders in the industry.

We work alongside clients to develop solutions for converting products from metal, wood, fiberglass and other materials into wholly integrated, rotationally molded plastic designs.

Requests for custom rotomolding (CRM) projects can be submitted through our website or by phone.

If you can dream it, we can build it!

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  • Knowledgeable in-house research & development and design/engineering team
  • Design assistance and project management
  • SolidWorks 3D modeling
  • NSF/UL assistance


  • In-house fabricated sheet metal tooling
  • CNC aluminum tooling
  • Cast aluminum tooling
  • In-house mold maintenance & repair
  • In-house fabricated jigs (foaming & cooling)
  • Surface finish (polish to many textures)

Quality Control

  • Powder flow analysis
  • Particle analysis
  • Dyne level testing
  • Water/air testing
  • Sample Inspection
  • Controlled processes

Secondary Operations

  • Urethane rigid foam filling
  • Part trimming, drilling & routing
  • Spin welding
  • Packaging
  • Part assembly/kitting
  • Shipping/Drop Ship
  • Branding (adhesive, mold-in)
  • Flame polishing
  • Insert molding
  • Custom color matching

Benefits of Rotational Moulding

  • Shorter lead-time from concept to production
  • One-Piece construction
  • Design flexibility from small to large products
  • Lower tooling cost
  • Resistant to stress-cracking and corrosion
  • Strength and durability
  • Stress free/low pressure process
  • Economical to do smaller production runs


Rotomolding Equipment

  • 4 – Rotational Molding 3-arm turret machines with swing up to 170”, Including the newest Ferry 330HD
  • IRT (Infrared Thermometry System Control)
  • 3D Prototype printing
  • Plastic plasma treater
  • CNC Routers
  • 4 – Large format digital printers


The IRP Custom Rotomolding Process

Custom Rotomolding Project Inquiries

IRP’s custom rotational molding, design and product engineering teams design and manufacture rotomolded, plastic products and parts of all kinds for OEMs and other companies in every industry. With a history of skill and expertise beginning in 1983, we work with companies to develop solutions for converting products from metal, wood, fiberglass and other materials into wholly integrated, rotationally molded plastic designs. We specialize in custom rotomolding projects for commercial and industrial products. Have an idea for a project? Get in touch with our CRM team today.

Begin your Custom Rotomolded project!