INTRODUCTION FOR PLASTIC INJECTION MOULDING DEFECTS PREVENTION & ROOT CAUSE ANALYSIS

Specifically designed for the practicing designer and molder.

This workshop focuses on prevention methods for defects and developing systematic root cause analysis skills. For solving molded-part defects and improving part quality problems.

COURSE OBJECTIVE

• How to prevent defects from occurring in the first place?
• Eighty % of plastic parts problems originate from poor design.
• Gap analysis between DFM (Design for Manufacturing best practices) and your actual problems
• Root cause analysis
• Troubleshooting injection moulding defects in a systematic manner
• Implementing sustainable measures in place to prevent defects recurrence
• Scientific explanations on why these problems occur

INTENDED AUDIENCE

This course is recommended for those who wish to improve their preventive & problem solving skills in plastic injection moulding design and process. It is also highly beneficial to companies aiming to improve productivity and optimise their injection moulding design and process methodology. A variety of people will benefit from this course. They include:

• Managers
• Designers
• Engineers
• Executives
• Supervisors
• Technicians
• Any technical personnel involved with plastic injection moulded parts

PREREQUISITE 

• Participants must already have the basics of injection moulding technology.
• Customer to provide ahead 5 top common issues that they have and the specific parts so that the trainer can use these as case studies during the training for optimum training effectiveness.

METHODOLOGY

• Interactive and action based with personal examples.
• Combination of short lectures, visual presentations, workshops, demonstrations, simulations, and games.
• More emphasis is placed on workshops to allow the participants to learn the material presented in a fun and easy manner.

DURATION

• 14 hours online

COURSE CONTENT

• Plastic drying
  • Degradation
  • Drying time
  • Drying temperature
  • Types of dryers
  • Moisture measurement
  • Overdrying effect

• Process optimization & scientific molding
  • Optimization of injection phase
  • Cavity balance
  • Pressure drop
  • Process windowGate seal time
  • Cooling time
  • Screw speed & back pressure

• Surface Defects
  • Flow lines and jetting
  • Splay (moisture or trapped air)
  • Haze, blush, and poor gloss
  • Mold mark
  • Gate blush and gate splay
  • Ink smearing
  • Incomplete molding
  • Race tracking
  • Jetting
  • Moldflow simulation errors

• Burning and Contamination Problems
  • Burn marks and black specks
  • Burn streaks
  • Contamination
  • Discoloration or poor color match

• Physical Problems
  • Flash
  • Short shots
  • Sink marks
  • Vacuum voids and bubbles
  • Burrs
  • Bulging
  • Overweight
  • Ejector marks

• Geometry Maintenance Problems
  • Under- or over-sized dimensions
  • Poor dimensional repeatability (poor Cpk)
  • Warpage and bowing

• Structural Defects
  • Cracking, crazing, and brittleness
  • Weld lines
  • Stuck parts and pin push marks
  • Long gates and plugged gates
  • Drag marks and mold damage
  • Break during assembly
  • Break after usage

• Troubleshooting Procedures and Logic
  • How to effectively approach, analyze, and implement troubleshooting procedures.

• Exploring Root Causes
  • Explore the root causes of the various defects from the perspective of the plastic material as it fills, compresses, and cools within the cavity.

• Part Defectives and Potential Solutions
  • How to avoid potential design-related problems?
  • How to optimize the part quality with process-related solutions?

• Troubleshooting Guides (The Good, The Bad, The Efficient)
  • A comparison of the different troubleshooting guide formats, including which tend to be most effective for solving molded part problems.

• Evaluating Attendees’ Molded Part Samples
  • Defective part samples brought in by the participants will be discussed in a group format.
  • An understanding by the participants of the processing conditions or a current process set-up sheet will greatly facilitate this discussion.

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