INTRODUCTION FOR PLASTIC INJECTION MOULDING – PROCESS OPTIMIZATION DEFECTS TROUBLESHOOTING 

This is a course of continuing education specifically designed for technical personnel in the plastic industry who wish to deepen their knowledge of injection moulding process and improve their problem-solving skills in injection moulding. Companies desiring to improve and optimize their plastic injection moulding process, reduce part rejects, increase productivity and/or solve their existing process variation problems will find this course highly relevant and useful.

The course expounds on the plastic injection moulding process and its machine and process parameters affecting the success and quality of moulded products. With this knowledge, the course will then focus on the optimization of the injection moulding process. It also provides a detailed discussion on multi-stage injection control and essential tips for saving moulding cycle time. The course also offers an in-depth discussion of the various types of injection moulding defects, the diagnosis of these defects and the remedies. These defects are commonly caused by the lack of process controls, poor part design, inadequate mould design, unsuitable choice of material, or any combinations of these factors. The course instructor will draw on his extensive experience in plastic injection moulding to illustrate the subject matter with practical examples. There will be group discussions and classroom exercises to maximize the learning and knowledge dissemination. Attendees are encouraged to bring along samples of moulding defects for added benefits of diagnosis and discussion during the course.

COURSE OBJECTIVES

• understanding of plastic materials
• plastic injection moulding process and process optimization
• tips for saving moulding cycle time
• multi-stage injection control for problem solving
• shrinkage and warpage, and how to eliminate warpage
• troubleshooting injection moulding defects
• major moulding defects when moulding semi-crystalline engineering polymers and remedies

COURSE CONTENT

DAY 1

• Introduction to Scientific Processing
  • The 5 critical factors of molding

• Introduction to Polymers & Plastics
• • Mold filling speed
  • Melt processing range
  • Mold temperatures
  • Barrel heat profile
  • Screw recovery speeds
  • Nozzle temperature control
  • Cooling times

• Polymer Rheology
• • Viscosity
  • Flow imbalance

• Plastic Drying
• • Hygroscopic polymers
  • Drying tempereatures & times
  • Drying equipment
  • Moisture measurement

• Injection molding machine specifications
• • Clamp force calculation
  • Shot size
  • Screw diameter and L/D ratio
  • Plasticating capacity

DAY 2

• Scientific processing & molding
  • Process robustness
  • Process consistency
  • The injection molding cycle
  • Process optimization

• The Aesthetic, Dimensional & Control Process Window

• Mold Qualification Flowchart

• Production Release

• Miscellaneous topics affecting the process
  • Mold cooling
  • Venting
  • Regrind

• Troubleshooting injection molding defects

INTENDED AUDIENCE

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

• product designers
• mould designers
• mould makers
• moulding engineers
• process engineers
• project engineers
• manufacturing engineers
• production engineers
• any technical personnel involved with plastic injection moulded parts

PREREQUISITE

Some technical familiarity and/or working experience in plastic injection moulding industry.

METHODOLOGY

• This course is conducted in a seminar room
• 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

• 2 Days

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