Complete Injection Molding

Course Number: AP5224
Date: 06/26/2013 - 06/28/2013
Time: 8:00 AM - 4:00 PM
Location: Akron Polymer Training Center, Akron, OH 44325-5404
Cost: $1,400 USD
CEU's: 1.9
Instructor: John Hickman

Course Overview

This 2 1/2 day course covers injection molding processes from machine and tooling to the production of high quality parts. Advanced injection molding principles that will be presented include tooling/design, plastic material behavior and avoiding molding defects. The instructor will discuss scientific molding including pressure and thermal transducers for maximizing control. The course focuses on the development of troubleshooting skills and the specific needs of each individual class member. All students are welcome to bring samples for discussion to formulate possible solutions. Concepts discussed in the classroom will be reinforced with "hands-on" activities in the Akron Polymer Training Center's laboratory.

Please note: 8:00 a.m. - 4:00 p.m. on first two days; 8:00 a.m. - 12:00 p.m. on third day

Course Outline

The Injection Molding Machine

• Selecting the right machine
• Determining shot capacity
• Heat profiles

Material Fundamentals

• Heat reaction
• Orientation
• Melt index

Molding Machine Overview

• Plasticizing unit
• Clamp unit

Injection Molds

• Types
• Components
• Gates
• Runners
• Mold finishes

Injection Molded Parts

• Parts produced with this process

Machine/Process Controls

• The relationship of controls to material flow characteristics and part performance
• Microprocessors
• Boost pressure
• Pack and hold pressure
• Elements of the molding cycle

Auxiliary Equipment

• Grinders
• Dryers
• Material handling
• Auto loaders

Types of Machines

• Traditional
• Two color
• Co-injection
• Gas assist

Material Review

• Material behavior in the molding process

Molding Machine

• Plasticizing unit
• Screws
• Pressures
• Drives
• Speed

Clamping Unit

• Clamp sizing
• Clamp types
• Ejector systems

Injection Molds

• Components
• Runners
• Gates
• Venting
• Ejection
• Geometry

Injection Molded Parts

• Basics of part design and the effect on the process

Machine/Process Controls

• Think like a molecule! The effect of molding process parameters at the molecular level
• Optimizing the process to produce quality parts

Goals/Outcomes

• Understand the proper terminology to help solve molding problems
• Learn to consistently produce quality parts
• Understand how properly set machine controls can cut scrap and cycle time
• Gain a better understanding of the entire molding process by learning more about your machines and their capabilities
• Learn what it takes to recognize molding defects and how to correct them
• Become familiar with basic design considerations
• Gain a better understanding of material behavior in the molding process
• Develop your troubleshooting skills

Who Should Attend: This course is designed for plastics professionals including engineers, managers, quality assurance, manufacturing and sales personnel desiring to build upon a solid foundation in the area of injection molding.

Testimonials:

"Real world examples helped illustrate the topics. Overall, a great experience! Will definitely recommend to others."

- Debbie Richie, Strategic Sourcing Specialist, Invacare Corporation

"John (instructor) is obviously extremely well-versed in this technology. He also has a vast body of practical experience which makes his examples more 'believable' and impactful."

- Kushal Baird, President, KMB Enterprises Incorporated