For rotational molding, Everflon™ ETFE GS40 powder is placed inside a hollow metal structure that is slowly rotated biaxially and heated above the melting point of the powder around 257 °C.

Frequently, the mold or part containing the resin is preheated (with rotation) to a temperature just below the melting point of the resin. Then, the temperature is raised to above the melting point of the resin to allow for formation of the lining. As the powder melts, it is deposited on the inner surface of the structure. Powder flow and distribution are critical, because the high melt viscosity of Everflon™ ETFE limits the lateral flow of melted resin. A cooling step then causes the molten resin to solidify and densify in place, creating an integral lining or a removable, hollow plastic part. A typical thickness is about 2mm . A thickness as high as 5mm has been molded.

Good moldings and linings require close attention to many details, such as choice of metals for the mold, preparation of the metal surface, rate of rotation, venting, and heating/ cooling cycles. The equipment must operate at high temperature and resist thermal shock.

The times and temperatures of the preheat, fusion, and cooling cycles will vary according to the part, oven, and choice of cooling method, etc. For a wall/lining thickness of 2, the following times and temperatures are typical.
Preheat 5 min at 250 °C
Fusion 60 min at 288 °C
Cooling (ambient air)

Within certain limits, the fusion temperature can be increased to permit shorter cycle times. The minimum time/temperature conditions can be defined as those times, at a specified temperature, that just allow for formation of bubble-free parts and linings. A typical minimum time/temperature relationship for Everflon™ ETFE GS40 is:
280°C/100 min
290°C/60min
295°C/50min

Everflon™ ETFE is relatively dense, compared to other resins. As a guide, to form a 2mm lining on a part with an interior surface of 0.1m2, use 360g of Everflon™ ETFE GS40.

Rotations for major and minor axes that are conventionally used for rotocasting other polymer resins have been applied without modification to Everflon™ ETFE GS40. For example, 8 rpm major, 9 rpm minor for boxes, cylindrical pipe sections, tees, spool pieces, etc.; 8 rpm major, 10 rpm minor for spheres and ellipsoids.These conventional rotations have given acceptable fluoroplastic resin distribution and casting thicknesses.

Molds must be vented during the rotational molding/ rotolining cycle. For best results, use an appropriate tube as a vent with glass wool in the tube to restrict contaminants from entering the part.