Scientific Molding Guru

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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
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
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.
Course 1: 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
Course 2: Purging Procedures
  • Phase 1 – Preparation
  • Phase 2 – Initial Purging
  • Phase 3 – Final Purging
  • Phase 4 – Production
Course 3: Purging Compounds
  • Common types of Compounds
  • Resin-Based Purging Compounds
  • Mechanical Purging Compounds
  • Chemical Purging Compounds
Course 4: Purging Cost Analysis
  • Purging Compound Cost
  • Machine Downtime Cost
  • Purging Labor Cost
  • Final Production Resin Cost
  • Scrap and Rework Costs
Electric Injection Molding

Our two Electric Injection Molding courses will provide participants with a better understanding of the benefits and capabilities of modern all-electric injection molding machines. Safety concerns particular to electric molding machines are also covered.

Course 1: Understanding Electric Injection Molding Machines
This training program will provide participants with a better understanding of how electric injection molding machines function – as well as the many benefits and capabilities associated with electric molding machines.
  • General Injection Molding Safety
  • Electric Molding Machine Safety
  • Machine Guarding
  • Comparing Hydraulic and Electric Machines
  • Basic Molding Machine Functions
  • Efficiency, Accuracy and Repeatability
  • Alternative Machine Designs
  • Typical Uses for Electric Injection Molding Machines
Course 2: Processing with Electric Injection Molding Machines
Packed with in-depth processing information, this course will undoubtedly prepare processors for making more appropriate and cost-effective decisions. Participants will also learn how to optimize any process that’s running on an electric injection molding machine.
  • Closed-Loop Process Controls
  • Hydraulic vs. Electric Molding Machine Controls
  • 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
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
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™
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 Series

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.

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

Level 2 : Scientific Molding Professional Certification Exam

Testing Categories:
  • Basic Equipment & Machinery Maintenance
  • Die Setting & Material Handling
  • Scientific Molding Process & Documentation
  • Scientific Purging
  • Scientific Troubleshooting
  • Tooling Fundamentals
Practical Skills Categories:
  • 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