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Plastic Part Failure Analysis

Course# Date Time Location
042-1045 09/26/2022 - 09/27/2022 8:30 AM - 4:30 PM Microsoft Teams
Cost: $1,400.00 USD
Online Registration
CEU's: 1.6
Instructor: Dr. Erol Sancaktar

Course Overview

This course has been designed to provide basic understanding of the fundamental issues regarding the design of injection-molded plastic parts (especially those used in automotive applications) to avoid undesirable outcomes and failure. It aims to provide basic knowledge of injection molding process and design for efficient manufacturing and performance. Characteristics and properties of commonly used plastics (especially those used in automotive components) are related to their process and performance characteristics. For this purpose, discussions on part defects (i.e., sink, flow line, stress concentration, etc.; their causes and design methods to avoid them are provided. Recent advances in process, design and testing methods are also covered. The course provides complete information on process variables and how they impact the part, as well as quality control processes and the ability to troubleshoot the process.

The topical coverage for the “Plastic Part Failure Analysis” course can be summarized in the Course Outline below.

Online Course Requirements

We want you to have a great experience participating in our remote (online) courses, and for that, you’ll need the right equipment and internet connection.

Minimum needs are:

  • A broadband internet connection that has at least a 2 Mbps upload and download speed.
  • A computer (PC or Mac) that can support the latest web browser versions.
  • At least 4 GB of RAM and adequate hard drive space.
  • A microphone and a speaker.
  • International Students: For virtual (online) courses, an additional fee will be assessed to cover the cost of shipping the professional binder (presentation slides), to your address. The cost of international shipping can be significant.

For more information, visit our Online Course Requirements webpage.

Instructor Biography:

Dr. Erol Sancaktar received his Ph.D. (Eng. Mechanics) and M.S. (Mech. Eng.) degrees from Virginia Tech. He is a Fellow of ASME and has served as Chair of ASME Tech. Committee on Reliability Stress Analysis, and Failure Prevention (1997-2008, 2013-present). He served as Associate Editor for the ASME J. Mech. Design (1995-2006) and Medical Devices (2006-2013). He was a faculty member at the Mechanical Eng. Dept. at Clarkson University during 1978 to 1996 before joining Univ. Akron in 1996 as Professor of Polymer Eng. He was also appointed Professor of Mechanical Eng. in 2009. Dr. Sancaktar currently holds the title, Professor Emeritus at the University of Akron’s School of Polymer Science and Polymer Engineering (since August 2020). Prof. Sancaktar edited 25 books and Journal Special Issues, authored 111 refereed journal articles, 30 articles in books edited by others, including 2 chapters in ASM Engineered Materials Handbook, as well as two chapters in Handbook of Adhesion Technology by Springer. He delivered 244 technical presentations and has 4 patents. Dr. Sancaktar organized 30 Conferences.

Dr. Sancaktar served in 15 different Federal Government review panels and served as reviewer for numerous scientific research proposals, journal articles and books. He had over 18 consulting assignments, sabbatical and extended visits with various government agencies (i.e., NASA, U.S. Army), industrial establishments (Kendall Co., Chrysler Corp.), foundations and legal agencies, not counting one-day consulting/advising visits. Among these expert services was an over-billion-dollar case and expert witness testimony at the U.S. International Trade Commission (2017).

Prof. Sancaktar and co-workers obtained ~ $4M Research and Grant support with 56 projects during 1980-2022. These include 8 National Science Foundation grants (~ $1.1M and spanning over 25 years), 3 Teaching Grants and 20 projects sponsored by Industry.

Course Content Overview:

  1. Material selection
    1. Defining the application environment - time, temperature, stresses, etc.
    2. Amorphous and semi-crystalline polymers
    3. The importance of molecular weight
    4. Structural choices within a polymer family
    5. Material properties
    6. Property modifiers and additives
    7. Performance and processability
    8. Establishing the cost/performance balance
  2. Failure analysis tools and processes
    1. Material testing - composition and degradation
    2. Molecular weight evaluations
    3. Thermal Analysis - DSC, TGA, DMA, TMA
    4. Spectroscopy- FTIR, EDS, XPS
    5. Microscopy - cross sections and scanning electron microscopy
    6. Physical property evaluation
  3. Elements of a successful plastic product
    1. Part design
    2. Mold design
    3. Material selection
    4. Processing
  4. Principles of plastic part design
    1. Nominal walls
    2. Ribs and other projections
    3. Holes and other depressions
    4. Designing for manufacturing and assembly
    5. Design properties versus inherent properties of materials
  5. Mold design considerations
    1. Mold steel selection
    2. Managing polymer flow in the mold - runners and gates
    3. Cavitation and the effect on balanced flow
    4. The economics of cavitation
    5. Hot runners versus conventional cold runners
    6. Mold temperature control
    7. Draft angles and ejection
  6. Case Studies


    If you have any questions or need more information about this course, please contact:

    Penelope Pinkston


    Online Registration


    Registration Form

    Registration information: Registration shall remain open until posted as closed on the course listing on this site.

    Registrations must be guaranteed by check, a purchase order number or a credit card, otherwise the registration will not be processed. Checks should be made payable to "The Akron Polymer Technology Services Training Center" and must include a copy of your completed registration form. Course fees are due before attending.

    All registrations—whether by online, phone, fax or mail—will be confirmed and considered binding and subject to all cancellation policies. If you do not receive a confirmation prior to the class, please call The Akron Polymer Technology Services Training Center to verify your registration.

    Course fee includes classroom instruction, instructional materials, parking permits, continental breakfast, lunch, beverages and refreshment breaks. Travel and hotel accommodations are not included.


    Visit our registration webpage to view our cancellation/withdrawal policy.