INTRODUCTION TO PLASTICS INJECTION MOULDING- INTENSIVE STRATEGIES FOR A STABLE & REPEATABLE PROCESS :

Are you familiar with the following sounds of instability:

• The process cannot be repeated.
• Every startup turns into trouble shooting
• 10 minutes of troubleshooting turns into a full day of knob turning & adjustment
• “Injection molding process must always be tweaked”
• “Something has changed. We will compensate by adjusting. Find out the root cause later”
• “This part can only be moulded by Technician A. Call him in now.”
• “It’s a design problem” – but you have moulded good parts before.
• “The tool must been modified” – but you have been running good parts on this tool for years
• Why we can produce good parts in Europe but not when the tool is transferred to Malaysia?

These are some of the common complaints heard on the Injection Moulding workshop when we have an instable process. How to overcome these problems that increases your material scrap cost, takes up machine valuable time and saps your energy?

COURSE OBJECTIVES:

• Understanding the 3 types of consistencies required in Injection Moulding
• Understanding the 5 critical Factors of Injection Moulding
• Explores the injection molding process with focus on making process improvements
• Discusses how changing processing conditions affects molded part properties
• Explains specific rules for controlling the plastic during processing
• Provides thorough overview of injection molding and troubleshooting techniques.
• Exercise greater control over the molding process
• Reduce rejects and scrap
•  Improve part quality
•  Increase productivity

INTENDED AUDIENCE:

This 2 days workshop has been designed for Section Heads, Engineers, Senior Technicians, Quality Technicians and Setup Technicians who are involved in the process of Plastic Injection Moulding and want to make their workplace more Productive with Quality.

METHODOLOGY:

The workshop is a mixture of presentation with personal examples, videos, discussions and group activities.

DURATION:

2 days

OUTLINE OF WORKSHOP:

• Introduction to plastic processing
  • Introduction
  • Thermodynamic principles governing injection molding

• Shrinkage & Warpage
  • In-Mold Shrinkage
  • Warpage
  • Post-Mold Shrinkage

• Causes of Molded-Part Variation: Part Design
  • Wall thickness
  • Ribs
  • Bosses

• Causes of Molded-Part Variation: Material
  • Resins
  • Pigments
  • Shrinkage Predictions

• Causes of Molded-Part Variation: Mold Design
  • Cavity
  • Gate types
  • Gate location
  • Gate size
  • Gate design system
  • Runner design
  • Mold-cooling design

• Causes of Molded-Part Variation: Processing
  • Molding conditions
  • Injection temperature
  • Injection rate & pressure
  • Holding pressure & time
  • Mold temperature
  • Summary and wrap up

• Common defects, their Causes & Prevention
  • Packing & Fill Problems
  • Surface Defects
  • Dimensional & Physical Problems

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