Simplified Movement Model to Predict the Thickness Distribution of Products Made by Robomould®

ABSTRACT Robotic rotational molding represents a major advancement over conventional techniques by integrating automation, electric heating, and advanced cooling. This process enables cost‐effective production of stress‐free hollow polymer parts with improved quality. A key development is the Robomould system, which uses a robotic arm to control mold movement and electrically heated molds instead of a traditional oven, allowing for superior control over the layer‐thickness distribution. Although the Robomould concept targets a wide range of product geometries, the experimental validation in this work focuses on a single axisymmetric 82 L liner without internal features. Typically, a rock‐and‐roll movement is applied, but current practice still relies on trial and error to define suitable movement and heating parameters, often causing long set‐up phases. To address this, a simple and computationally inexpensive movement model is proposed to estimate thickness distribution for given parameters. The model considers only product geometry and movement, neglecting thermal effects and dynamic powder effects. A volumetric mesh of the product is used to simulate powder distribution, and the powder–mold contact time of each element is translated into local thickness distribution estimation. Despite its simplicity, experimental validation demonstrates strong predictive value, supporting faster process set‐up by reducing reliance on trial and error.