*** Please note, each row and course# listed below is a separate, complete course. ***

Plastic Part Failure Analysis

Course# Date Time Location
042-1188 09/30/2024 - 10/01/2024 8:30 AM - 4:30 PM Microsoft Teams
042-1189 07/17/2025 - 07/18/2025 8:30 AM - 4:30 PM Microsoft Teams
042-1190 09/24/2025 - 09/25/2025 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 two-day course covers basic issues regarding the design of injection-molded plastic parts aiming to improve knowledge of injection molding process, design for manufacturing and information on causes of low-quality parts production and part failure. For that purpose, it covers how the tooling works and moves; undercut treatment (e g., lifter, slide, horn pin, ejector, A-core, etc.); part defects (e g., sink, flow line, etc.); design techniques for good material flow and for sink mark reduction; attachment methods and considerations (e.g., bolts, tapping screws, snap fits, creep, etc.) The course also provides information on characteristics and properties of plastics commonly used in automotive and related industries (e.g., PP, ABS, POM, LLDPE, Nylon, etc.). Expected audience includes design engineers, process engineers, product engineers, rubber compounders, chemists, laboratory managers, R&D scientists, technical service representatives and material suppliers. Limited plastic design experience (very little to none) and low knowledge of tool design should be sufficient to benefit from this course.

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:

The following topics will be covered:

  • Blending and alloying
  • Blisters
  • Bosses
  • Burns
  • Colorants
  • Cooling systems/types/geometry
  • Crystallization
  • Design methodology
  • Design of ribs
  • Draft
  • Ejection pin types/location/marks
  • Failure analysis methodology
  • Fillers
  • Flame retardants
  • Flash/Deflashing
  • Forming undercuts using lifters and slides
  • Frozen-in-stresses
  • Gating types/location/geometry
  • Holes and other depressions
  • Knit lines
  • Materials/Material selection
  • Mold flow
  • Parting lines
  • Rheology
  • Ribs and other projections
  • Runner systems/balance/geometry
  • Shrinkage
  • Sink
  • Venting systems/location/geometry
  • Snap tabs
  • Support structures
  • Techniques
  • Texture
  • Tools
  • Wall thickness
  • Warpage
  • Weld Lines
  • Microporosity

Section Titles:

  • Contributions to Failure
  • Injection Mold Basics; Components
  • Injection Molding Process
  • Product Design
  • Mold Design
  • Case Studies
  • Clamping
  • Revisit Product Failure
  • Revisit Product Design; Examples
  • Troubleshooting
  • Material Properties and Tests
  • Digital Product Development
  • Moldex3D Computer Aided Engineering (CAE) Design
  • Case Studies Revisited
  • Material Selection
  • Design Methods and Analysis
  • Case Studies Revisited


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.