The Plastics Training Specialists

Scientific Process Engineer Package

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Scientific Process Engineer Package

The online courses in this package are selected to lay the foundation of knowledge necessary for the success of any Scientific Molder.

Our unique Scientific SkillSet Labs allow you to practice and learn critical Scientific Molding Skills used in Developing and Documenting a Robust Injection Molding Process.

Anyone involved in Process Development, Trials, Qualification, and Troubleshooting will benefit greatly from this package.

Package Course Descriptions:

Introduction to Injection Molding

This course provides participants with a general introduction to the plastics industry. The primary focus of this training program is the day-to-day operations of a typical injection molding facility.

An Introduction to Injection Molding was created for newcomers to the injection molding industry or anyone that would like to learn more about plastics. We recommend that new hires take this course before participating in our Injection Molding Basics series.

An overview of plastics and the industry
- A typical molding facility
- General plant safety
- An introduction to the molding process
- Molding machine components
- Material handling
- Injection mold terminology
- Common part defects

Injection Molding Basics

Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs.

These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.

Part 1: Machine

- Cites important safety precautions for working around injection molding machines
- Gives an introduction to the injection molding process
- Introduces machine types and the different modes of operation
- Discusses injection molding machine components and their respective functions
- General procedures for starting up and shutting down a molding machine

Part 2: Process

- Discusses polymers and the three criteria used to classify them
- Covers some of the more common procedures for material preparation
- Introduces the three phases of the molding process; injection, cooling and ejection
- Explains the need for maintaining an accurate process log
- Defines common injection molded part defects and explains their causes

Part 3: Mold

- Explains the specific functions that an injection mold must perform
- Introduces the various machining methods used to construct an injection mold
- Discusses the three mold configurations used in the industry
- Covers common runner shapes and gate types used in injection molds
- Gives an overview of proper injection mold maintenance

Understanding Plastics

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.

- The definition of plastics
- Polymer classification
- Material properties affected by processing
- Proper material handling techniques
- Processing characteristics of virgin and regrind

Establishing a Scientific Molding Process

This scientific molding training course provides participants with in-depth processing information to better prepare them for making appropriate and cost-effective decisions when establishing or improving a scientific injection molding process.

The course teaches a processing strategy that properly decouples 1st stage fill from 2nd stage pack. Students who understand and utilize the strategy described in this course will produce processes with a much higher repeatability. The steps outlined in this course are intended to quickly establish a scientific injection molding process, reduce downtime and improve process efficiency.

- General Rules for Scientific Processing
- Scientific Process Optimization Strategies:
- 1st Stage Filling
- 1st Stage to 2nd Stage Transfer
- 2nd Stage Pack
- Screw Delay
- Screw Recovery
- Screw Decompression
- Cooling Time
- Mold Opening
- Part Ejection
- Mold Closing
- Clamping

Scientific SkillSet™ Series

The Scientific SkillSet™ Series is a unique learning experience that combines detailed, step-by-step online instruction with practical hands-on labs and worksheets.

Each of the twenty-six course/worksheet combinations focuses on developing important processing-related skills that translate directly to troubleshooting, optimizing and documenting any injection molding process.

This exclusive training approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort of their own production environment. Your employees will learn how to setup a repeatable process and troubleshoot effectively through Scientific Molding.

Each unique training course is a blend of the following components:

Your technicians understand the goal of each Scientific SkillSet™

Technicians learn specifically how each Scientific SkillSet™ applies to their job

Items are detailed to ensure techs have the tools they need to succeed

Each step is demonstrated so your techs can proceed with confidence

Contains all the information your techs need to succeed with each SkillSet™

What’s Covered in the Scientific Skillset™ Series?

The Scientific SkillSet™ labs teach a sound scientific approach to injection molding. With more than 2 dozen distinct skills being taught, your technicians can quickly learn how to apply proven Scientific Molding techniques to everyday molding processes.

Your processors and technicians will receive over 18 hours of online SkillSet™ instruction and hands-on labs to confidently develop the following abilities:

Melt Temperature Measurement
Accurately measure & document the polymer temperature.

Mold Temperature Measurement
Accurately measure & document mold and coolant temperatures.

Process Documentation
Document your process for easy duplication and scientific troubleshooting.

1st Stage Fill Progression
Learn how the mold actually fills and identify problem areas.

1st Stage Injection Speed
Quickly find an acceptable injection rate for part quality.

1st Stage Injection Transfer
Set 1st to 2nd stage transfer to accommodate for variation.

1st Stage Injection Pressure
Determine a safe maximum injection pressure to help protect the mold.

1st Stage Injection Time
Set a maximum injection time and prevent excessive injection.

2nd Stage Packing Pressure
Find the optimal packing pressure between sinks and flash.

2nd Stage Packing Time
Determine gate seal time and optimize your packing time.

2nd Stage Final Cushion
Prevent bottoming-out while maximizing pressure transfer.

2nd Stage Clamp Force
Set clamping to protect the mold & maximize venting effectiveness.

Coolant Temperature
Establish the optimal mold coolant temperature controller settings.

Cooling Time
Determine an optimized cooling time while compensating for normal variation.

Rear Zone Temperature
Use the rear zone to conserve energy & maximize melting capacity.

Screw Recovery Time
Protect the quality & integrity of your polymer during melting.

Mold Opening
Optimize the clamp settings while protecting your part quality.

Part Ejection
Optimize part removal while maintaining your overall part quality.

Mold Closing
Optimize the clamp settings while protecting your mold & actions.

Mold Protect Force
Reduce the potential for mold damage when problems occur.

1st Stage Cavity Imbalance
Determine which speed provides the best filling balance.

1st Stage Rheology Curve
Determine the speed at which shear thinning takes place.

Comparative Rheology
Compare materials, grades, lots, additives, temperatures, etc.

1st Stage Check Ring
Evaluate the functionality of the check ring during injection.

Measuring Mold Deflection
For benchmarking and troubleshooting mold deflection issues.

Measuring Platen Deflection
For benchmarking and troubleshooting platen deflection issues.