package includes:

 

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

Injection Mold Setup

This comprehensive 2-part program provides participants with a better understanding of die setting including safety preparation, documentation, mold removal & installation, and process startup. This is an excellent course for anyone involved in die setting including process technicians and supervisors.

Injection Mold Setup, Program 1

• Safety Concerns and Considerations for Die Setters
• Injection Mold Setup Scheduling and Preparation
• Machine Dependent and Independent Documentation
• Proper Injection Mold Preparation and Examination
• Safe and Effective Mold Removal Techniques

Injection Mold Setup, Program 2

• Safe and Effective Mold Installation Techniques
• Setting Clamp Tonnage and Mold Protect
• Optimizing Clamp and Part Ejection Settings
• Establishing Consistent Screw Recovery
• Melt Temperature Matching Techniques
• Process Startup and Scientific Molding Principles

Material Drying Technology

Routsis Training’s two Material Drying Technology online courses provide participants with a better understanding of how different polymers are best dried and prepared for reliable processing. These courses show participants how proper plastics material handling and drying is critical to produce a consistent product and process. Course One reviews polymer basics, as well as both hygroscopic and non-hygroscopic polymers – to better convey the importance of properly drying water-sensitive materials.

Material Drying Technology, Course 1

• Polymer Basics
• Hygroscopic vs. Non-Hygroscopic Polymers
• Hydrolysis
• Purposes of Drying
• Dewpoint
• Dewpoint Measurement
• Dewpoint Sensors
• Drying Procedures

Material Drying Technology, Course 2

• Hot Air Dryers
• Compressed Air Dryers
• Desiccant Dryers
• Vacuum Dyers
• Calculating Material Consumption
• Calculating Residence Time
• Calculating Dryer Capacity

Automation & Robotics for Scientific Molding

These training programs will provide participants with a better understanding of how automation and robotics are used to streamline production within the injection molding industry.

Automation and Robotics for Scientific Molding, Part 1

This training program will provide participants with a better understanding of the different options and capabilities associated with automation.

• Guarding and Safety Considerations
• Types of Automation Used for Injection Molding

Automation and Robotics for Scientific Molding, Part 2

This training program will provide participants with a better understanding of the different options and capabilities associated with robotics.

• Controllers and Movements of Robotics
• End-of-Arm Tooling
• Sprue Pickers
• Top-Entry Robots
• Side-Entry Robots
• Articulating Robots
• Examples of Robotics

Purging for Scientific Molders

The four online training courses in Routsis’s Purging series will teach scientific injection molders about proper material purging concepts and procedures.

The first two courses cover common purging techniques and effective purging procedures – while the third course details common types of purging compounds, how they work, and the advantages and disadvantages of each type. In the final course, users are shown how to effectively compare different purging procedures and compounds – and guided through completion of the accompanying Purging Analysis Worksheet.

We've also developed a Purging Cost Analyzer “app” that runs on both PCs and Macs – as well as iOS and Android devices. This powerful, free tool complements the online training courses and allows users to quickly and easily compare various purging compounds and/or methods.

Purging Techniques

• Definition of Purging
• General Injection Molding Safety
• Injection Molding Machine Safety
• Plastic Purging Safety
• The Purpose of Purging
• Small and Large Shot Purging
• Continuous and Closed-Mold Purging
• Dry and Wet Purging
• Purging Heat Sensitive Materials
• Purging High Temperature Materials
• Hot Runner and Gate Drop Cleaning
• Nozzle and Screw Removal

Purging Procedures

• Phase 1 – Preparation
• Phase 2 – Initial Purging
• Phase 3 – Final Purging
• Phase 4 – Production

Purging Compounds

• Common types of Compounds
• Resin-Based Purging Compounds
• Mechanical Purging Compounds
• Chemical Purging Compounds

Purging Cost Analysis

• Purging Compound Cost
• Machine Downtime Cost
• Purging Labor Cost
• Final Production Resin Cost
• Scrap and Rework Costs

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.

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

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

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

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™

Train On Your Computer, Tablet or Smartphone

Our Scientific SkillSet™ online courses are cross-platform and are compatible with most modern web browsers and popular handheld devices, such as tablets and smartphones. This provides exceptional flexibility, allowing technicians to train at their own pace on the production floor – without costly trainers or consultants.

What’s Covered in the Scientific Skillset™ Series?

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.

Injection Molding Machine Maintenance

This online course is designed to introduce the many maintenance considerations for an injection molding machine. Participants are also shown newer technologies; such as laser leveling, ultrasonic tie bar stretch measuring, and portable machine process monitors.

• Basic machine maintenance and safety concerns
• Fluid maintenance
• Platen maintenance
• Screw and barrel maintenance
• Preventative maintenance and logging

Injection Molding Hydraulics

These online training courses demonstrate the importance of hydraulics – and the proper maintenance of hydraulic components – in the injection molding process. Machine operators will learn ways to reduce wear on hydraulic components, while more advanced employees concentrate on hydraulic print reading and theory.

• Basic hydraulic theory
• The role of hydraulics in injection molding
• The function and purpose of hydraulic components
• Recognition of hydraulic symbols
• Directional valves and flow controls
• Hydraulic pumps and motors
• Proportional valves and servo valves
• Hydraulic fluid management

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

Level 2 : Scientific Molding Professional Certification Exam

Routsis Training’s Professional Injection Molding Certification is globally recognized. Moving beyond the basics covered in our Level 1 exam, Level 2 certification requires an advanced understanding of Scientific Molding. Participants must also demonstrate hands-on skills in order to attain certification. The standards in this examination are determined by current industry best practices.

Passing the Online Testing portion requires a good understanding of scientific processing and documentation, as well as die setting, material handling, purging, troubleshooting, and tooling.

The Skills Testing portion of the examination demands a functional demonstration of practical Scientific Injection Molding, including: scientific process development, process documentation, and other critical skills.

Who Should Consider Certification:

Level 2 certification is geared toward engineers and technicians. In short, anyone involved with developing and optimizing Scientific Molding processes can benefit from this enhanced certification. Individuals who get certified can further their careers and improve their standing with their company and the industry at large. Molding and engineering managers should consider offering this certification as a means of verifying they have a confident, capable team.

How to Get Certified:

In order to ensure candidates have both working knowledge and demonstratable skills, our Level 2 Scientific Molding Professional Certification testing is conducted in 2 stages: an Online Test and Hands-on Skills Testing.

The first stage involves completing a comprehensive Online Test, which requires approximately 1.5 hours — with a total time limit of 3 hours. Upon completion of the exam, participants are immediately notified whether they’ve passed or not, via email. Within several days, those who do not pass receive a detailed report indicating areas in which further improvement is needed.

The Skills Testing stage involves completion of hands-on worksheets at an injection molding machine. Portions of these sessions must be recorded on video — as proof that the candidate completed these materials. The completed materials must uploaded to us for individual review before certification is conferred upon the candidate.

Online Exam Question Categories:

• Basic Equipment & Machinery Maintenance
• Die Setting & Material Handling
• Scientific Molding Process & Documentation
• Scientific Purging
• Scientific Troubleshooting
• Tooling Fundamentals

Practical Skills Demonstrations:

• Melt Temperature Measurement
• Coolant Temperature Measurement
• Scientific Process Documentation
• 1st Stage Check Ring Evaluation
• 1st Stage Injection Transfer
• 1st Stage Injection Pressure Setpoint
• 1st Stage Injection Time Setpoint
• 2nd Stage Packing Pressure Study
• 2nd Stage Packing Time Study
• 2nd Stage Final Cushion Setpoint
• 2nd Stage Clamp Force Study
• Screw Recovery Time

How to Prepare for Level 2 Certification:

Although preparation training is not necessary to achieve certification, participation in Routsis’s Scientific Injection Molding programs can greatly increase a candidate’s chances of passing the exam. Most of our corporate customers use Routsis Training’s exclusive RightStart™ in-house employee development system, as well as our SkillSet™ hands-on labs. For individuals and small companies, we offer an online training package specifically geared toward preparing for and attaining Level 2 certification.