Scientific Troubleshooting for Injection Molders
These four in-depth scientific molding training programs provide participants with the knowledge base required to identify 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
Processing For Profit
Processing for Profit is intended to provide injection molding processors and technicians with industry-proven procedures and techniques which can be used to easily improve the efficiency and profitability of any molding application.
- Definition of Scientific Molding
- Scientific Process Optimization
- Part Removal
- General Rules for Efficient Processing
- Die Setting
- The 5S System
Scientific SkillSet™ Series
The Scientific SkillSet™ Series is a unique learning experience that combines detailed, step-by-step online instruction with practical hands-on labs and worksheets.
Each of the twenty-six course/worksheet combinations focuses on developing important processing-related skills that translate directly to troubleshooting, optimizing and documenting any injection molding process.
This exclusive training approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort of their own production environment. Your employees will learn how to setup a repeatable process and troubleshoot effectively through Scientific Molding.
Each unique training course is a blend of the following components:
BACKGROUND: Your technicians understand the goal of each Scientific SkillSet™
PURPOSE: Technicians learn specifically how each Scientific SkillSet™ applies to their job
EQUIPMENT: Items are detailed to ensure techs have the tools they need to succeed
PROCEDURE: Each step is demonstrated so your techs can proceed with confidence
WORKSHEET: Contains all the information your techs need to succeed with each SkillSet™
The Scientific SkillSet™ labs teach a sound scientific approach to injection molding. With more than 2 dozen distinct skills being taught, your technicians can quickly learn how to apply proven Scientific Molding techniques to everyday molding processes.
Your processors and technicians will receive over 18 hours of online SkillSet™ instruction and hands-on labs to confidently develop the following abilities:
Melt Temperature Measurement
Accurately measure & document the polymer temperature.
Mold Temperature Measurement
Accurately measure & document mold and coolant temperatures.
Process Documentation
Document your process for easy duplication and scientific troubleshooting.
1st Stage Fill Progression
Learn how the mold actually fills and identify problem areas.
1st Stage Injection Speed
Quickly find an acceptable injection rate for part quality.
1st Stage Injection Transfer
Set 1st to 2nd stage transfer to accommodate for variation.
1st Stage Injection Pressure
Determine a safe maximum injection pressure to help protect the mold.
1st Stage Injection Time
Set a maximum injection time and prevent excessive injection.
2nd Stage Packing Pressure
Find the optimal packing pressure between sinks and flash.
2nd Stage Packing Time
Determine gate seal time and optimize your packing time.
2nd Stage Final Cushion
Prevent bottoming-out while maximizing pressure transfer.
2nd Stage Clamp Force
Set clamping to protect the mold & maximize venting effectiveness.
Coolant Temperature
Establish the optimal mold coolant temperature controller settings.
Cooling Time
Determine an optimized cooling time while compensating for normal variation.
Rear Zone Temperature
Use the rear zone to conserve energy & maximize melting capacity.
Screw Recovery Time
Protect the quality & integrity of your polymer during melting.
Mold Opening
Optimize the clamp settings while protecting your part quality.
Part Ejection
Optimize part removal while maintaining your overall part quality.
Mold Closing
Optimize the clamp settings while protecting your mold & actions.
Mold Protect Force
Reduce the potential for mold damage when problems occur.
1st Stage Cavity Imbalance
Determine which speed provides the best filling balance.
1st Stage Rheology Curve
Determine the speed at which shear thinning takes place.
Comparative Rheology
Compare materials, grades, lots, additives, temperatures, etc.
1st Stage Check Ring
Evaluate the functionality of the check ring during injection.
Measuring Mold Deflection
For benchmarking and troubleshooting mold deflection issues.
Measuring Platen Deflection
For benchmarking and troubleshooting platen deflection issues.
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.
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
- 1st Stage Injection
- 2nd Stage Packing
- Part Cooling
- Screw Recovery
- Part Removal
- Understand Basic Machine Controls
- Differentiating Modes of Operation
- Understanding Common Part Removal Techniques
- Knowledge of Common Visual Defects
- Flash
- Short Shots
- Sinks & Voids
- Jetting
- Burning
- Flow Lines
- Weld and Meld Lines
- Poor Surface Finish
- General Hot Runner Systems
- Conventional Mold Bases
- General Material Characterization
- Basic Dimensions and Tolerances
- Understanding Material Handling
- Material Drying Methods
- Start-Up and Shut-Down
- General Material-Related Defects
- Splay
- Bubbles and Blisters
- Brittleness, Cracking and Crazing
- Delamination
- Contamination
- 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
