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3 Day Intermediate Scientific Molding Training

This package is intended to provide the participant with an extended, well-rounded understanding of injection molding with a knowledge-based certification once all the training is complete. This process is a proven and effective system designed to combine a variety of training techniques into an effective learning experience.

Prerequisite Training

  • Injection Molding Basics
  • Understanding Plastics Materials
  • Establishing a Scientific Molding Process

Learning Objectives

  • Understand safety precautions around the molding machine
  • Introduces the molding machine, process, mold, & material
  • Identify machine components and understand their functions
  • General injection molding machine startup and shutdown
  • Common polymers types and their general classifications
  • Understand the purpose and importance of a process log
  • Visual injection molding defects and their typical causes
  • Identifying basic injection mold components and functions
  • Hot and cold runners systems and common gating methods
  • Basic injection mold maintenance during production
  • Material properties which are affected by processing
  • Basic material handling and drying techniques
  • Establishing an efficient scientific molding process
  • Basic scientific process optimization strategies for:
    • 1st Stage Filling
    • 1st Stage to 2nd Stage Transfer
    • 2nd Stage Pack
    • Screw Delay
    • Screw Recovery
    • Screw Decompression
    • Cooling Time
    • Mold Opening
    • Part Ejection
    • Mold Closing
    • Clamping

Day 1 : Classroom Discussion Topics

  • Scientific Molding – Safety
  • Scientific Molding – Rules of Processing
  • Scientific Molding – Inputs vs. Outputs
  • Scientific Molding – 1st Stage Injection
  • Scientific Molding – 2nd Stage Packing

Day 1 : Practical Skill Development

  • Scientific Molding – Melt Temperature Measurement
  • Scientific Molding – Mold Temperature Measurement
  • Scientific Molding – 1stStage Injection Fill Progression
  • Scientific Molding – 1stStage Injection Speed Optimization
  • Scientific Molding – 1stStage Injection Transfer Optimization
  • Scientific Molding – Maximum 1stStage Injection Pressure
  • Scientific Molding – Maximum 1stStage Injection Time

Day 1 : Skills & Learning Objectives

  • The importance of good housekeeping and machine safety
  • Machine guarding and personal protective equipment
  • Industry best practices for processing and troubleshooting
  • 5 rules of effective and efficient scientific processing
  • Understanding process parameters for 1ststage injection
  • Basic optimization of 1ststage injection and transfer
  • Fundamental scientific (DII or short shot molding) methodology
  • Proper setting of maximum 1ststage injection pressure
  • Correct and incorrect uses of injection velocity profiling
  • Transferring 1ststage injection to 2nd stage pressure by weight
  • Understanding process parameters for 2ndstage packing
  • Properly compensating for material shrinkage with pressure
  • Effective 2ndstage packing pressure establishment techniques
  • 2ndstage packing time determination using part weight
  • Proper cushion sizing techniques to compensate for variation
  • Difference between melt temperature and barrel temperature
  • Proper material temperature measurement techniques
  • Proper melt temperature and mold temperature documentation
  • Demonstrating the mold gating and filling patterns
  • Establishing a 90 to 95% 1ststage fill based on part weight

Day 2 : Classroom Discussion Topics

  • Scientific Molding – Screw Recovery
  • Scientific Molding – Part Cooling
  • Scientific Molding – Material Drying Technology

Day 2 : Practical Skill Development

  • Scientific Molding – 2ndStage Packing Pressure Optimization
  • Scientific Molding – 2ndStage Packing Time Optimization
  • Scientific Molding – 2ndStage Final Cushion Optimization
  • Scientific Molding – 2ndStage Clamp Force Optimization

Day 2 : Skills & Learning Objectives

  • Understanding process parameters for screw recovery
  • Screw decompression both before & after screw recovery
  • Minimizing the stresses imposed on the material
  • How to reduce screw flex and breakage during recovery
  • Reduction of energy consumption during shot generation
  • Proper uses for back pressure during screw recovery
  • Melt and mold temperature measurement technique review
  • Proper melt temperature matching troubleshooting techniques
  • Difference between mold, coolant, and controller temperatures
  • Optimal mold temperature determination techniques
  • Review of the steps to determine the most efficient cooling time
  • How hydrolysis causes increased polymer chain degradation
  • Uses for material drying including effective pre-heating techniques
  • Basic operation of hot air, compressed air, desiccant, and vacuum dryer systems
  • Different methods for removing both absorbed and surface moisture
  • Explanation of drying concepts including relative humidity and dewpoint
  • Effective and reliable portable dewpoint measurement techniques
  • Determination of upper and lower acceptable packing pressures
  • Optimization of final packing pressure to compensate for variation
  • Practical gate seal time determine techniques
  • Manual graphing of part weight vs. 2ndstage packing time
  • Selection of optimal 2ndstage packing time for variation compensation
  • Techniques for obtaining the optimal final cushion sizing
  • Adjustments to shot size and transfer position for proper cushion sizing

Day 3 : Classroom Discussion Topics

  • Scientific Molding – Hydraulic vs. Plastic Pressure
  • Scientific Molding – Electric Molding Machines
  • Scientific Molding – Process Documentation
  • Scientific Molding – Intro to Troubleshooting

Day 3 : Practical Skill Development

  • Scientific Molding – Coolant Temperature Optimization
  • Scientific Molding – Cooling Time Optimization
  • Scientific Molding – Screw Recovery Optimization
  • Scientific Molding – Process Documentation

Day 3 : Skills & Learning Objectives

  • Understanding the difference between hydraulic and plastic pressure
  • Common hydraulic to plastic pressure conversion techniques
  • Understanding all-electric molding machine control systems
  • Review of the difference between electric and hydraulic machine controls
  • Proper machine independent process documentation techniques
  • Effective machine independent process documentation techniques for:
    • 1st Stage Injection
    • 2nd Stage Packing
    • Part Cooling
    • Material Recovery
    • Mold Clamping
  • The definition and role of a scientific troubleshooter
  • Scientific vs. non-scientific process documentation techniques
  • The difference between conventional and scientific troubleshooting
  • An introduction to proper scientific troubleshooting techniques
  • The 7 steps to the effective scientific troubleshooting
  • The role of scientific documentation in proper documentation
  • Performing a cooling time study to determine minimal cooling time
  • Calculating the optimal cooling time which compensates for variation
  • Practice setting of screw recovery to minimize material degradation
  • Performing effective machine independent process documentation

Post-Requisite Online Training

  • Scientific Troubleshooting for Injection Molders

Post-Requisite Learning Objectives

  • The 7 steps to the effective scientific troubleshooting in detail
  • Using proper process documentation to your advantage
  • Identification, causes, and effective troubleshooting techniques for fixing:
    • Flash
    • Sinks & Voids
    • Short Shots
    • Jetting
    • Gate Blush
    • Burning
    • Flow Lines
    • Weld & Meld Lines
    • Poor Surface Finish
    • Large Parts
    • Differential Part Dimensions
    • Part Warpage
    • Splay, Bubbles, & Blisters
    • Brittleness, Cracking, & Crazing
    • Delamination
    • Contamination
    • Poor Color Distribution, Part Sticking, Ejector Pin Marks, Occasional Part Hang-up
  • Email Specific Request for Services