Request for Quote

Rotational Molding of MDPE Forced Air Housing Shell for HVAC Industry

A client in the Solar Heating Industry contacted Rhino, Inc. for design assistance and manufacturing of an MDPE forced air housing with an insulating EPS foam core. The housings were to be used in a solar collection forced air heating system. Once we determined performance and functional specifications, we began working on mold design and manufacturability specifications. With tooling complete, we moved right into production. Secondary processes involved trimming of parting lines, application of graphics, and inserting/forming the EPS foam core.

The housing exteriors were made of MDPE, and the interior cavity consisted of EPS foam. A 550 shot peen finish was applied to the exterior surface of the part, with a mill finish interior allowing us to provide multiple surface textures for both functionality and aesthetics.

Critical dimensions were identified and executed on the interior cavity of the part to hold dimensional tolerances in proportion with additional components with differing heat expansion coefficients. The final product was 79.5 inches long, 5.25 inches high, 39.5 inches wide and weighed 60 pounds.


To learn more about this project, or for more information on our other products and services, please contact Rhino, Inc.

Request for Quote

Rotational Molding of MDPE Forced Air Housing Shell - Project Details

Product Description These Rotational Molded Forced Air Housing Shells are used in solar powered forced air heating systems
Capabilities Applied/Processes Roto-Molding
Mold Manufacturing
  • CNC Machine Aluminum Mold in Rhino's Tooling Shop -American Roto Tool (ART)


Secondary Operations
  • Trim Parting Lines
  • Apply Secondary Graphic
  • EPS Foam Core
Overall Part Dimensions Length: 79.5"
Width: 39.5"
Height: 5.25"
Temperature Range Ambient to inconsistent Peaks Reaching 150 degrees F
Material Used Exterior Skin:  MDPE

Internal Core:  EPS Foam

Componenet Finish Interior Cavity:  Mill Finish
Exterior:  550 Shot Peen
Color    Compounded Tan

Light Gray


Special Features EPS Foam-Filled Cavity

Must Hold DImensional Tolerances in Proportion w/ Additional Components comprised of different materials (with differing heat expansion coefificients

In Process Testing / Inspection Performed Post-Foam Dimensional Verification
Estimated Part Weight

Finished Part - 60 Lbs

Industry for Use HVAC


Product Name    Forced Air Housing Shell

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