Corner / Edge Radius for Rotational Moulding
As a general guide internal and external corners of rotational mouldings should have a minimum radius of 2mm. This ensures the powders will fuse evenly around or in to the corners. With an even wall thickness, internal stresses are reduced and weak points eliminated.
Products are often designed with larger radii. This can be to dissipate structural forces over a greater area. They are also used for purely aesthetic reasons, unlike fabrications, there are virtually no limits to the designers imagination.
2mm Is not a hard and fast rule. The following factors can be considered.
Internal corners are the most critical, without a radius, material may not build up to the desired wall thickness. Acute angles will need a larger radius, obtuse will need less.
External corners can have much less of a radius depending on the material and overall design especially if the corner angle is less than 90 degrees. If the corner angle is more than 90 degrees it will often need a radius greater than 2mm. Sharp edges are possible on surface details.
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