package includes:

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

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

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

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

Mold Design & Moldmaking

This comprehensive 9-part online training program was created with help from many of the world's leading tool manufacturers and suppliers and is intended for tool designers, mold makers, engineers, part designers, and anyone involved in the tool procurement process.

The Mold Design and Moldmaking Series familiarizes participants with the different types of injection molds, contemporary machining methods, and many of the available mold components. This course also provides the participant with a tool design methodology and a sample mold specification guide for reference.

Injection Mold Fundamentals

• The four basic functions of an injection mold
• Part design considerations
• Material considerations
• Molding machine considerations
• Initial mold design

Mold Machining Methods, Part 1

• Conventional and CNC milling
• Conventional and CNC lathe
• Conventional and CNC surface grinding
• The advantages and disadvantages to each machining method
• Finishes and stresses with each process

Mold Machining Methods, Part 2

• Conventional and CNC die sinking EDM
• CNC wire EDM
• Polishing
• Inspection equipment
• Seal-offs

2-Plate, 3-Plate, and Hot Runner Molds

• Explains the three basic mold designs and their construction
• Advantage and disadvantage to each design
• Common uses for each design
• Explains different hot runner systems
• Parting line locks
• Specialty molds

Mold Bases, Tool Steels & Heat Treating

• Tooling materials and their properties
• Various heat treating methods
• Introduces alternative materials, such as Beryllium-copper
• Features DME standardized mold bases

External and Internal Actions

• Slides, core pins, & lifters
• Unscrewing & expandable cores
• Inserts
• Dissolvable cores
• Preload and seal-offs

Part Ejection, Venting and Cooling

• Ejector pins, sleeves, blades and lifters
• Stripper plates and pneumatic ejection
• Water lines, bubblers, baffles and conductive cooling rods
• Multi-stage ejection and ejection return
• Covers different forms of part venting

Gating Methods

• Commonly used Gates and their characteristics
• Introduction to hot runner gate design
• Introduction to cold runner gate design
• Explains manual and automatic gate removal
• Discusses gate location determination

Runners, Filling Software & The Mold Design Process

• Parting line determination and considerations
• Core and cavity block configuration
• Cooling line and ejection layout
• Additional mold components
• Mold filling analysis capabilities

Plastic Part Design

Plastic Part Design provides part designers with an understanding of the plastic part design process. This extensive, interactive online training program also addresses many of the factors and concerns associated with part design.

Dr. Robert Malloy, a respected author and professor at the University of Massachusetts, Lowell, developed these comprehensive courses.

Course 1: Product Development & The Prototype Process

• The development & prototype process
• Product development steps
• Concurrent engineering
• Computer simulations for design
• Rapid prototyping and tooling processes

Course 2: Mechanical Behavior of Polymers

• The mechanical behavior of polymers
• Stress/strain curves
• Visco-elastic behavior of polymers
• Creep and stress relaxation
• Fatigue and cyclic stress

Course 3: Mold Filling, Gating & Weld Lines

• Gating & weld line considerations
• Mold filling processes
• Gate types, location, and importance
• Weld line occurrence and strength determination

Course 4: Shrinkage, Warpage, & Part Ejection

• How packing affects shrinkage and warpage
• The effects of part geometry
• Amorphous vs. semi-crystalline behavior
• Ejection systems for simple and complex geometry

Course 5: Mechanical Fasteners, Press & Snap Fits

• Assembly techniques
• Snap fit design and considerations
• Design for assembly and disassembly
• Boss and screw design
• Press fit design and strength equations

Course 6: Welding & Adhesives Bonding Technology

• Various part welding processes
• Joint design for injection molded parts
• Adhesive bonding applications & techniques
• Wetting, surface attraction and curing of adhesives