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
Process Documentation for Scientific Molders
This training program will provide participants with a better understanding of proper documentation and the procedures associated with documenting a scientific molding process.
The comprehensive course teaches the differences between machine-dependent and machine-independent process parameters as well as the importance of proper documentation for each. Students will also learn the necessary procedures associated with documenting and maintaining a robust scientific injection molding process.
- Definition of Scientific Process Documentation
- Inputs vs. Outputs
- Machine-Dependent Documentation
- Machine-Independent Process Documentation
- Documenting Barrel & Recovery
- Documenting 1st Stage Injection
- Documenting 2nd Stage Packing
- Documenting Part Cooling
- Documenting Mold Clamping
- Hybrid Machine & Process Documentation
- Documenting All Process Changes
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
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
