Professional Certification Portal for Mold & Part Design

A Professional Certification Portal from Routsis Training delivers essential eLearning to your entire workforce. Their newfound knowledge and skills translate directly into increased productivity and profitability for your company.

Your new “Cert Portal” comes pre-configured with our most effective online training courses. Employees start with the basics and quickly progress to intermediate and advanced topics; teaching them the skills they’ll need to consistently deliver quality products to your customers.

These preconfigured portals provide the most cost-effective way to train your entire workforce.

 

Injection Molding Fundamentals

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

Level 1 Certification Training

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

Blueprint Reading

The six programs in our online blueprint reading training course develop workers’ abilities to accurately locate and interpret dimensions on engineering drawings. These training programs are based on ANSI standards and incorporate input from a broad industrial cross-section.

The primary audience is production and inspection personnel, supervisors, group leaders, set-up personnel, and anyone who wishes to read engineering drawings.

Course 1: Introduction to Engineering Drawings

• Explains the purpose of an engineering drawing
• Distinguish between a detail drawing and an assembly drawing
• Interpret the drawing scale
• Explains the purpose of dimensions and tolerances

Course 2: Multiview Drawings

• The six principal views of a third-angle projection
• Identify the ISO symbols for third-angle and first-angle projections
• Auxiliary views, partial views, and enlarged views
• Determine which line takes precedence over another

Course 3: Sectional Views

• Determine which portion of the part is shown in section
• Explain the purpose of section lines and identify the ways in which they are used
• Identify and interpret the common drafting conventions applied to sectional views

Course 4: Dimensions and Tolerances, Part 1

• Identify the size and/or location for a given part feature
• Correctly calculate the tolerance specified for a given part feature

Course 5: Dimensions and Tolerances, Part 2

• Locate and interpret dimensions specified by chain, baseline and direct dimensioning methods
• Identify a datum feature and explain its purpose
• Explain how maximum material condition (MMC) and least material condition (LMC) apply to internal and external features
• Calculate allowance
• Identify a surface finish specification

Course 6: Part Feature Specifications

• Identifies twelve of the most common part features on a drawing
• How to correctly interpret part specifications

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

Injection Mold & Part Design Certification Exam

Routsis Training’s globally recognized Professional Certification demonstrates a broad-spectrum understanding of the injection molded part and mold design.

To attain certification, candidates must have a working knowledge of mold and part design fundamentals, print reading, mathematics, basic scientific molding concepts, and plastics materials — and demonstrate a solid understanding of current industry best practices.

Who Should Consider Certification:

This Design certification program is primarily intended for design engineers and process engineers. Individuals can use this certification to help advance their careers and industry standing. Engineering managers should considers offering this certification as part of a broader training strategy. A certified workforce is better able to rise to the challenges of a modern manufacturing environment, instilling confidence in management and customers alike.

How to Get Certified:

This comprehensive exam is conducted entirely online. The test takes approximately 1.5 hours to complete — with a time limit of 3 hours. Upon completion of the exam, participants are immediately notified whether they’ve passed or not, via email.

Those who attain a passing score will receive their certificate. Those who do not pass receive a detailed report indicating areas in which further improvement is needed.

Question Categories:

• Basic Scientific Molding
• Injection Mold Basics
• Basic Dimensions & Mathematics
• Plastics Materials
• Plastics Part Design
• Tooling Design Fundamentals

How to Prepare for Certification:

Although preparatory training is not necessary to achieve certification, most design professionals use our RightStart™ in-house employee development system to prepare for this exam. Individuals can prepare for and take the exam as part of our Injection Mold & Part Design Professional Certification Package.