The Plastics Training Specialists

Scientific Die Setter Package

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The courses in this online training package are perfect for Die Setters and Technicians. Courses include basic injection molding, mold setup, process establishment and troubleshooting.

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

Process Documentation for Scientific Molders 

This training program will provide participants with a better understanding of proper documentation and the procedures associated with documenting a scientific molding process. 
The comprehensive course teaches the differences between machine-dependent and machine-independent process parameters as well as the importance of proper documentation for each. Students will also learn the necessary procedures associated with documenting and maintaining a robust scientific molding process. 

- the Definition of scientific process documentation
- Inputs vs. Outputs
- Machine-Dependent Documentation
- Machine-Independent Process Documentation
- Documenting Barrel & Recovery
- Documenting 1st Stage Injection
- Documenting 2nd Stage Packing
- Documenting Part Cooling
- Documenting Mold Clamping
- Hybrid Machine & Process Documentation
- Documenting All Process Changes

Processing Parameters for Scientific Molding

This 3-part training program will provide participants with a better understanding of the parameters involved with a scientific injection molding process and the control panels of injection molding machines.

This course is beneficial to die setters, process technicians, maintenance personnel, engineers, and anyone else using the control panel.

Part 1 - Introduction

- Scientific Molding Overview
- 5 General Rules for Scientific Molding
- Understanding the Process Controller
- Common Units for Process Parameters

Part 2 - Process

- Process Inputs versus Process Outputs
- 1st Stage Injection Inputs and Outputs
- 2nd Stage Packing Inputs and Outputs
- Cooling Inputs and Outputs
- Screw Recovery Inputs and Outputs
- Other Commonly Found Process Inputs

Part 3 - Part Removal

- Mold Open Settings
- Part Ejection Settings
- Core Pull Settings
- Mold Closing Settings

Injection Mold Setup

This comprehensive 2-part program provides participants with a better understanding of die setting including safety preparation, documentation, mold removal & installation, and process startup. This is an excellent course for anyone involved in die setting including process technicians and supervisors.

Injection Mold Setup, Program 1

- Safety Concerns and Considerations for Die Setters
- Injection Mold Setup Scheduling and Preparation
- Machine Dependent and Independent Documentation
- Proper Injection Mold Preparation and Examination
- Safe and Effective Mold Removal Techniques

Injection Mold Setup, Program 2

- Safe and Effective Mold Installation Techniques
- Setting Clamp Tonnage and Mold Protect
- Optimizing Clamp and Part Ejection Settings
- Establishing Consistent Screw Recovery
- Melt Temperature Matching Techniques
- Process Startup and Scientific Molding Principles

Automation and Robotics for Scientific Molders

This comprehensive 2-part program provides participants with a better understanding of how automation and robotics are used to streamline production within the injection molding industry. Using standard industry terms and practices with an emphasis on safety, this series will enhance the knowledge base of all production personnel involved with automation and robotics.

Automation and Robotics, Program 1

- General Automation & Robotics Safety
- Common Guarding for Automation & Robotics
- Common Automation for Injection Molding

Automation and Robotics, Program 2
- Controllers & Movements of Robotics
- End-of-Arm Tooling
- Sprue Pickers
- Top-Entry Robots
- Side-Entry Robots
- Articulating Robots
- Examples of Robotics

Purging for Scientific Molders Series

The four courses in Routsis's Purging training program will teach scientific injection molders about proper material purging concepts and procedures.

The first two courses cover common purging techniques and effective purging procedures – while the third course details common types of purging compounds, how they work, and the advantages and disadvantages of each type. In the final course, users are shown how to effectively compare different purging procedures and compounds – and guided through completion of the accompanying Purging Analysis Worksheet.
Purging Techniques
- Definition of Purging
- General Injection Molding Safety
- Injection Molding Machine Safety
- Plastic Purging Safety
- The Purpose of Purging
- Small vs. Large Shot Purging
- Continuous and Closed-Mold Purging
- Dry vs. Wet Purging
- Purging Heat Sensitive Materials
- Purging High Temperature Materials
- Hot Runner and Gate Drop Cleaning
- Nozzle and Screw Removal

Purging Procedures
- Phase 1 – Preparation
- Phase 2 – Initial Purging
- Phase 3 – Final Purging
- Phase 4 – Production

Purging Compounds
- Common types of Compounds
- Resin-Based Purging Compounds
- Mechanical Purging Compounds
- Chemical Purging Compounds

Purging Cost Analysis Worksheet
- Purging Compound Cost
- Machine Downtime Cost
- Purging Labor Cost
- Final Production Resin Cost
- Scrap and Rework Costs

Injection Mold Maintenance

This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life and increase its productivity.

- Proper mold maintenance
- Mold storage and preparation
- Water line maintenance
- Techniques for extending tool life