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Injection Molding Professional Certification Package
Injection Molding Professional Certification Package
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Product Code: SM_205_US

Injection Molding Professional Certification Package

These courses are specifically focused on injection molding, this self-paced online package is specifically designed to provide the participant the necessary information to prepare for Level 1 Certification.

19 Online Courses & Certification (20-40 hours + Study Guides)

Package Course Descriptions:

Introduction to Injection Molding

This course provides participants with a general introduction to the plastics industry. The primary focus of this training program is the day-to-day operations of a typical injection molding facility.

An Introduction to Injection Molding was created for newcomers to the injection molding industry or anyone that would like to learn more about plastics. We recommend that new hires take this course before participating in our Injection Molding Basics series.

An overview of plastics and the industry
- A typical molding facility
- General plant safety
- An introduction to the molding process
- Molding machine components
- Material handling
- Injection mold terminology
- Common part defects

1 Online Course (1-2 hours + Study Guide)

Injection Molding Basics

Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs.

These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.

Part 1: Machine

- Cites important safety precautions for working around injection molding machines
- Gives an introduction to the injection molding process
- Introduces machine types and the different modes of operation
- Discusses injection molding machine components and their respective functions
- General procedures for starting up and shutting down a molding machine

Part 2: Process

- Discusses polymers and the three criteria used to classify them
- Covers some of the more common procedures for material preparation
- Introduces the three phases of the molding process; injection, cooling and ejection
- Explains the need for maintaining an accurate process log
Defines common injection molded part defects and explains their causes

Part 3: Mold

Explains the specific functions that an injection mold must perform
Introduces the various machining methods used to construct an injection mold
Discusses the three mold configurations used in the industry
Covers common runner shapes and gate types used in injection molds
Gives an overview of proper injection mold maintenance

3 Online Courses (3-6 hours + Study Guides)

Understanding Plastics

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.

- The definition of plastics
- Polymer classification
- Material properties affected by processing
- Proper material handling techniques
- Processing characteristics of virgin and regrind

1 Online Course (1-2 hours + Study Guides)

Establishing a Scientific Molding Process

This scientific molding training course provides participants with in-depth processing information to better prepare them for making appropriate and cost-effective decisions when establishing or improving a scientific injection molding process.

The course teaches a processing strategy that properly decouples 1st stage fill from 2nd stage pack. Students who understand and utilize the strategy described in this course will produce processes with a much higher repeatability. The steps outlined in this course are intended to quickly establish a scientific injection molding process, reduce downtime and improve process efficiency.

- General Rules for Scientific Processing
- Scientific Process Optimization Strategies:
- 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

1 Online Course (1-2 hours + Study Guide)

Processing Parameters for Scientific Molding

This 3-part training program will provide participants with a better understanding of the parameters involved with a scientific injection molding process and the control panels of injection molding machines.

This course is beneficial to die setters, process technicians, maintenance personnel, engineers, and anyone else using the control panel.

Part 1 - Introduction

- Scientific Molding Overview
- 5 General Rules for Scientific Molding
- Understanding the Process Controller
- Common Units for Process Parameters

Part 2 - Process

- Process Inputs versus Process Outputs
- 1st Stage Injection Inputs and Outputs
- 2nd Stage Packing Inputs and Outputs
- Cooling Inputs and Outputs
- Screw Recovery Inputs and Outputs
- Other Commonly Found Process Inputs

Part 3 - Part Removal

- Mold Open Settings
- Part Ejection Settings
- Core Pull Settings
- Mold Closing Settings

3 Online Courses (3-6 hours + Study Guides)

Material Drying Technology

Routsis Training’s two Material Drying Technology online courses provide participants with a better understanding of how different polymers are best dried and prepared for reliable processing. These courses show participants how proper plastics material handling and drying is critical to produce a consistent product and process. Course One reviews polymer basics, as well as both hygroscopic and non-hygroscopic polymers – to better convey the importance of properly drying water-sensitive materials.

Material Drying Technology, Course 1

- Polymer Basics
- Hygroscopic vs. Non-Hygroscopic Polymers
- Hydrolysis
- Purposes of Drying
- Dewpoint
- Dewpoint Measurement
- Dewpoint Sensors
- Drying Procedures

Material Drying Technology, Course 2

- Hot Air Dryers
- Compressed Air Dryers
- Desiccant Dryers
- Vacuum Dyers
- Calculating Material Consumption
- Calculating Residence Time
- Calculating Dryer Capacity

2 Online Courses (1-3 hours + Study Guides)

Electric Injection Molding

Our two Electric Injection Molding courses will provide participants with a better understanding of the benefits and capabilities of modern all-electric injection molding machines. Safety concerns particular to electric molding machines are also covered.

1: Understanding Electric Injection Molding Machines

This training program will provide participants with a better understanding of how electric injection molding machines function – as well as the many benefits and capabilities associated with electric molding machines.

- General Injection Molding Safety
- Electric Molding Machine Safety
- Machine Guarding
- Comparing Hydraulic and Electric Machines
- Basic Molding Machine Functions
- Efficiency, Accuracy and Repeatability
- Alternative Machine Designs
- Typical Uses for Electric Injection Molding Machines

2: Processing with Electric Injection Molding Machines

Packed with in-depth processing information, this course will undoubtedly prepare processors for making more appropriate and cost-effective decisions. Participants will also learn how to optimize any process that’s running on an electric injection molding machine.

- Closed-Loop Process Controls
- Hydraulic vs. Electric Molding Machine Controls
- Process Optimization Strategies:
- 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

2 Online Courses (2-3 hours + Study Guides)

Math for Molders

This two-part training program was created for all personnel within the injection molding industry who would like to expand or fine-tune their math skills.

These courses will greatly benefit any participant of RJG’s classroom-based Master Molder SM Certification Series either as a primer or as follow-up training.

Part 1

- Whole Numbers, Negative Numbers and Decimals
- Using a Calculator
- Addition, Subtraction, Multiplication and Division
- Rounding Numbers and Significant Figures
- Formulas, Equations and Order of Operations

Part 2

- Metric and Imperial Units
- Length and Distance
- Area, Volume & Flow
- Weight, Mass and Force
- Conversions
- Understanding Percentages
- Calculating Plastic Pressure and Part Shrinkage
- Calculating Tolerances

2 Online Courses (3-4 hours + Study Guides)

Scientific Troubleshooting for Injection Molders

These four in-depth scientific molding training programs provide participants with the knowledge base required to indentify and troubleshoot over twenty-five of the most common injection molded part defects. Users will also come away with a better understanding of how to best process, document and maintain a reliable scientific injection molding process.

Course 1: Introduction

This scientific molding training program focuses on the 7-step process to scientific troubleshooting. Participants are also presented with information and practices on how to best process, document and maintain a reliable scientific injection molding process.

Step 1 – Develop a Scientific Molding Process
Step 2 – Properly Document the Process Outputs
Step 3 – Examine the Defective Part and Rule Out Obvious Causes
Step 4 – Compare the Current Process with the Documented Process
Step 5 – Return the Process to the Documented Standard
Step 6 – Verify the Part and Process
Step 7 – Document all Changes Made

Course 2: Visual Defects

Nine of the most common visual defects encountered in injection molding processing are covered within this extensive scientific molding training program. Participants will be better prepared to troubleshoot these defects as each one will be defined and their respective causes and corrections will be explained in detail. Defects include:

- Flash
- Sinks and Voids
- Short Shots
- Jetting
- Gate Blush
- Burning
- Flow Lines
- Weld and Meld Lines
- Poor Surface Finish

Course 3: Dimensional Defects

This scientific injection molding training program will provide participants with a better understanding of how to best troubleshoot five (5) of the most common dimensional defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. These dimensional defects include:

- Large Parts
- Small Parts
- Larger Parts at the Gate
- Smaller Parts at the Gate
- Warpage

Course 4: Material and Cycle-Related Defects

After completing this scientific molding training program, participants will have a better understanding of how to best identify and troubleshoot many of the most common Material and Cycle-Related defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. The material and cycle-related defects discussed in this course include:

- Splay, Bubbles, and Blisters
- Brittleness, Cracking, and Crazing
- Delamination
- Contamination
- Poor Color Distribution
- Part Sticking and Ejector Pin Marks
- Occasional Part Hang-Up

4 Online Course (6-10 hours + Study Guides)

Certification for Injection Molding Professionals – Level 1

This globally-recognized professional certification demonstrates a broad-spectrum understanding of the injection molding industry. The knowledge required ranges from a good understanding of injection molding safety to having a fundamental working knowledge of injection molding machinery, processing, tooling, materials, and quality; all based on current industry best practices. Successfully passing this certification demonstrates a good working knowledge of injection molding and industry best practices.

Who Should Consider Certification?

Anyone working in the plastics industry should consider Level 1 Certification for Injection Molding Professionals. Individuals and engineers can use this certification to improve their standing within the industry or their company. Molding Managers should consider offering this certification to train a strong workforce confident with a fundamental understanding of injection molding.

How to Get Certified:

Level 1 Injection Molding Professional certification testing is conducted either online or in person at a certified plastics testing center. The Level 1 certification requires the completion of a 3-part test taking approximately 1-2 hours to complete with a time limit of 3 hours total. The first portion of the test consists of a series of True-False questions to cover a broad spectrum of content. The second section of testing consists of multiple-choice questions designed to better differentiate a candidates understanding of common injection molding concepts. The third portion of the testing requires analysis of common molding scenarios designed to identify the candidate’s working knowledge of injection molding.

Once the participant has successfully completed the Level 1 certification test, they will be immediately provided with a printable certificate. If you are located within the region of a certified testing center such as the Americas or Southeast Asia, you will receive, via post, a wallet sized certificate as well as a full-sized certificate suitable for framing. You records will also be kept on our global database, so additional awards, plaques, and certificate copies can be ordered at any time in the future.

How to Prepare for Certification:

Although preparation training is not necessary to achieve certification, most injection molding professionals prepare for Level 1 Certification testing with 16-24 hours of our online training programs.

Testing Criteria:

- Working Safely in an Injection Molding Environment
- Identifying Machine Components and Their Function
- Comparing Basics of Hydraulic vs. Electric Machinery
- Understanding the General Purpose Screw
- Familiarity with General Polymer Types
- Amorphous vs. Semi-Crystalline Materials
- Thermoplastics vs. Thermosets
- Familiarity with the Molding Process, including: 1st Stage Injection, 2nd Stage Packing, Part Cooling, Screw Recovery and Part Removal
- Understand Basic Machine Controls
- Differentiating Modes of Operation
- Understanding Common Part Removal Techniques
- Knowledge of Common Visual Defects, including: Flash, Short Shots, Sinks & Voids, Jetting, Burning, Flow Lines, Weld & Meld Lines and PoorSurface Finish.
- General Hot Runner Systems
- Conventional Mold Bases
- General Material Characterization
- Basic Dimensioning and Tolerances
- Understanding Material Handling
- Material Drying Methods
- Start-Up and Shut-Down
- General Material-Related Defects, including: Splay, Bubbles, & Blisters, Brittleness, Cracking & Crazing, Delamination, Contamination, and Poor Color Distribution
- Process Documentation Techniques
- Common Mold Machining Methods
- Conventional Gating Systems
- Typical Mold Maintenance Techniques
- Polymer Chain Orientation
- Basic Math and Common Calculations

Typical Testing Time 1-2 hours

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