New Product Development Process

Bushmans uses the rotational moulding plastics process to produce hollow and seamless parts, which are partially or totally enclosed. Bushmans produces moulded parts in various sizes and configurations, ranging from the size of a football to parts as large as 4 metres in diameter. Annual part quantities of 100 to 5,000 are common.

Let us see how the process works from your idea to a finished product ready for production. Most of our customer’s projects follow the Project flow chart on this page. What we will do is examine each of these sections in a little more detail to help you understand how Bushmans will deliver your custom rotationally moulded product.


Your sketch plans or 2-D or 3-D drawings will help us to produce costings for your tooling and the moulding of your parts. This tool is attached to an external frame, to hold it closed during the moulding process. The frame also allows us to attach the mould to the rotational moulding machine for producing your part

According to your specifications, we will mould the part with the wall thickness, colour, and material of your choosing. These parts can include moulded in features such as inserts and post moulding additions, such as graphics. After de-moulding it is on to post- moulding operations, such as trimming and final finishing. The end result is a part ready for assembly to your prototype!

Once we have final approval from you that your part will function as desired, we can begin producing your new part.

Rotational Moulding has always been known as a versatile manufacturing method for plastic parts. Over the past decade it has come of age in terms of responding to the need to provide high performance parts in demanding market sectors. In doing this, the process has retained its advantages of producing stress-free parts, available with short lead times and attractive economics.

The rotational moulding industry is a dynamic sector, with BUSHMANS always ready to respond to a challenge.