Our intermediate Scientific SkillSet™ labs provide a unique and valuable learning experience for your setup technicians, processors, and engineers. Only from Routsis Training, these innovative courses combine detailed, step-by-step online instruction with practical hands-on labs and worksheets.
This exclusive training approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort and convenience of their own production environment. All our Scientific Skillset™ products are available in English, French, Spanish, Portuguese, Bahasa Malaysia, and Mandarin Chinese.
Each of the 13 course/worksheet combinations in this group focuses on developing an important processing-related skill — demonstrated on your production equipment.
Melt Temperature Measurement
It’s important for processors to understand that the temperature of the polymer melt will differ from the barrel temperature settings. The purpose of this lab is to determine the actual temperature of the polymer being injected into the mold. Participants practice taking accurate polymer measurements and documenting the results on their worksheet.
Mold Temperature Measurement
Mold coolant is used to help cool the polymer, allowing the part to be ejected without damage or distortion. It’s critical that techs remember the actual mold temperature may be different that the chiller setpoint. In this lab, participants use a surface temperature probe to determine the actual temperature of the coolant entering and leaving the mold.
Process Documentation
Machine-independent process documentation is an essential component of Scientific Molding. This approach to documentation promotes easy troubleshooting and allows the process to be duplicated — even when run on a different molding machine.
1st Stage Injection Speed
Using a faster injection speed is an important step in optimizing the efficiency and consistency of the molding process. This lab teaches participants to quickly determine a fast injection speed that produces acceptable parts.
1st Stage Injection Transfer
In order to accommodate normal variations in the material and processing conditions, the transfer position of the screw needs to be optimized. The purpose of this lab is to establish a 1st stage short shot between 90 and 95% of the final part weight, which is measured and documented on the participant’s worksheet.
1st Stage Injection Pressure
It is important that your process always has adequate pressure available to ensure the machine can maintain the desired injection speed. The purpose of this lab is to determine the maximum injection pressure for your process, which will allow you to compensate for variations in the material and processing conditions.
1st Stage Injection Time
It is important that your process has adequate time available. A correctly-set injection time ensures the screw can travel from the shot size to the transfer position. The purpose of this lab is to determine the fastest 1st stage injection time for your process, while compensating for normal variations.
1st Stage Check Ring
In any Scientific Molding process, the check ring must be capable of providing a reliable, consistent amount of material during 1st stage fill. Participants evaluate and document the functionality of the check ring — to determine how consistently the molding machine is injecting material during 1st stage fill.
2nd Stage Packing Pressure
The purpose of this lab is to determine the lowest and highest packing pressures that create an acceptable part, and then to determine a final packing pressure setting. Participants find the optimal packing pressure by examining the parts for sinks or flash — and logging their findings.
2nd Stage Packing Time
Your process must have enough packing time to ensure the gate fully seals. In this lab, participants graph part vs. second stage weight — in order to determine the appropriate gate seal time for the process. Once determined, this value is used to derive the optimal second stage packing time.
2nd Stage Final Cushion
For most processes, the optimal cushion is around 10% of the overall shot size. The purpose of this lab is to adjust the shot size and transfer position to create an optimal cushion at the end of 2nd stage packing. This prevent bottoming-out while maximizing pressure transfer.
2nd Stage Clamp Force
Clamping must be set correctly in order to protect the mold and maximize the effectiveness of the mold vents. In this training lab, the participant determines the minimum amount of clamp force necessary to make an acceptable part, while compensating for normal process variations.
Screw Recovery Time
Optimal screw recovery protects the quality and integrity of your polymer during melting. In this lab, participants determine an appropriate recovery time — one that ensures the plastic material is not experiencing excessive shear, without wasting energy or time.
