INTRODUCTION FOR PLASTIC INJECTION MOULDING – UNDERSTANDING THE IMPORTANCE OF PART & TOOLING DESIGN

Plastic Injection Moulding parts are found in countless big and small products today, from computers, household goods, control and instrumentation equipments, road vehicles, sporting goods to biomedical instruments, just to name a few. The quality and finishing of the plastic products depends on understanding the importance of part & tooling design.

The course instructor will draw on his extensive experiences in plastic injection molding to illustrate the subject  matter with practical examples. Attendees can also bring along samples of moulding defects for diagnosis and discussion.

COURSE OBJECTIVES

• Plastic material selection
• Plastic part design
• DFMA for plastic parts
• Choice of secondary process

COURSE CONTENT

Day 1

• Product Development & The Prototype Process

• • The development & prototype process
  • Product development steps
  • Concurrent engineering
  • Computer simulations for design
  • Rapid prototyping and tooling processes

• Mechanical Behavior of Polymers

• • The mechanical behavior of polymers
  • Stress/strain curves
  • Visco-elastic behavior of polymers
  • Creep and stress relaxation

• Mold Filling, Gating & Weld Lines

• • Fatigue and cyclic stress
  • Gating & weld line considerations
  • Mold filling processes
  • Gate types, location, and importance
  • Weld line occurrence and strength determination

• Shrinkage, Warpage, & Part Ejection

• • How packing affects shrinkage and warpage
  • The effects of part geometry
  • Amorphous vs. semi-crystalline behavior
  • Ejection systems for simple and complex geometry

• Mechanical Fasteners, Press & Snap Fits

• • Assembly techniques
  • Snap fit design and considerations
  • Design for assembly and disassembly
  • Boss and screw design
  • Press fit design and strength equations

• Welding & Adhesives Bonding Technology

• • Various part welding processes
  • Joint design for injection molded parts
  • Adhesive bonding applications & techniques
  • Wetting, surface attraction and curing of adhesives

Day 2

• Mold Machining Methods

• • Conventional and CNC milling
  • Conventional and CNC lathe
  • Conventional and CNC surface grinding
  • The advantages and disadvantages to each machining method
  • Finishes and stresses with each process

• 2-Plate, 3-Plate, and Hot Runner Molds

• • Explains the three basic mold designs and their construction
  • Advantage and disadvantage to each design
  • Common uses for each design
  • Explains different hot runner systems
  • Parting line locks
  • Specialty molds

• Mold Bases, Tool Steels & Heat Treating

• • Tooling materials and their properties
  • Various heat treating methods
  • Introduces alternative materials, such as Beryllium-copper
  • Features DME standardized mold bases

• External and Internal Actions

• • Slides, core pins, & lifters
  • Unscrewing & expandable cores
  • Inserts
  • Dissolvable cores
  • Preload and seal-offs

• Part Ejection, Venting and Cooling

• • Ejector pins, sleeves, blades and lifters
  • Stripper plates and pneumatic ejection
  • Water lines, bubblers, baffles and conductive cooling rods
  • Multi-stage ejection and ejection return
  • Covers different forms of part venting

• Gating Methods

• • Commonly used Gates and their characteristics
  • Introduction to hot runner gate design
  • Introduction to cold runner gate design
  • Explains manual and automatic gate removal
  • Discusses gate location determination

• Runners, Filling Software & The Mold Design Process

• • Parting line determination and considerations
  • Core and cavity block configuration
  • Cooling line and ejection layout
  • Additional mold components
  • Mold filling analysis capabilities

HOW TO SEND US AN ENQUIRY?

1. Fill in the form below and submit it to us. A popup message “Thank you for your message, our sales person will contact you soon.” will appear after a few seconds.
2. Initiate a conversation via live chat on the bottom left of our website by stating: ‘Hi, my name is [your-name]. I’ve already submitted the form for this training.’
3. We’ll promptly reach out to you regarding the training you’re interested in.