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Scientific Molding 103 Package

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Injection Molding 103

Injection Molding 103 provides expert training for anyone looking to take their Scientific Molding Skills to the next level.
Included in this package is our Injeciton Molding Professional Certification Test - Level 1.
Participation in our Injection Molding 101 and Injection Molding 102 online training packages are recommended prior to participating in these programs.

Package Course Descriptions:

Scientific Troubleshooting for Injection Molders

These four in-depth scientific molding training programs provide participants with the knowledge base required to indentify and troubleshoot over twenty-five of the most common injection molded part defects. Users will also come away with a better understanding of how to best process, document and maintain a reliable scientific injection molding process.

Course 1: Introduction

This scientific molding training program focuses on the 7-step process to scientific troubleshooting. Participants are also presented with information and practices on how to best process, document and maintain a reliable scientific injection molding process.

Step 1 – Develop a Scientific Molding Process
Step 2 – Properly Document the Process Outputs
Step 3 – Examine the Defective Part and Rule Out Obvious Causes
Step 4 – Compare the Current Process with the Documented Process
Step 5 – Return the Process to the Documented Standard
Step 6 – Verify the Part and Process
Step 7 – Document all Changes Made

Course 2: Visual Defects

Nine of the most common visual defects encountered in injection molding processing are covered within this extensive scientific molding training program. Participants will be better prepared to troubleshoot these defects as each one will be defined and their respective causes and corrections will be explained in detail. Defects include:

- Flash
- Sinks and Voids
- Short Shots
- Jetting
- Gate Blush
- Burning
- Flow Lines
- Weld and Meld Lines
- Poor Surface Finish

Course 3: Dimensional Defects

This scientific injection molding training program will provide participants with a better understanding of how to best troubleshoot five (5) of the most common dimensional defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. These dimensional defects include:

- Large Parts
- Small Parts
- Larger Parts at the Gate
- Smaller Parts at the Gate
- Warpage

Course 4: Material and Cycle-Related Defects

After completing this scientific molding training program, participants will have a better understanding of how to best identify and troubleshoot many of the most common Material and Cycle-Related defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. The material and cycle-related defects discussed in this course include:

- Splay, Bubbles, and Blisters
- Brittleness, Cracking, and Crazing
- Delamination
- Contamination
- Poor Color Distribution
- Part Sticking and Ejector Pin Marks
- Occasional Part Hang-Up

Processing For Profit

Processing for Profit is intended to provide injection molding processors and technicians with industry-proven procedures and techniques which can be used to easily improve the efficiency and profitability of any molding application.

- Definition of Scientific Molding
- Scientific Process Optimization
- Part Removal
- General Rules for Efficient Processing
- Die Setting
- The 5S System

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:

BACKGROUND:
Your technicians understand the goal of each Scientific SkillSet™

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

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

PROCEDURE:
Each step is demonstrated so your techs can proceed with confidence

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

Our Scientific SkillSet™ online courses are cross-platform and are compatible with most modern web browsers and popular handheld devices, such as tablets and smartphones. This provides exceptional flexibility, allowing technicians to train at their own pace on the production floor – without costly trainers or consultants.

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.

Certification for Injection Molding Professionals – Level 1

This globally-recognized professional certification demonstrates a broad-spectrum understanding of the injection molding industry. The knowledge required ranges from a good understanding of injection molding safety to having a fundamental working knowledge of injection molding machinery, processing, tooling, materials, and quality; all based on current industry best practices. Successfully passing this certification demonstrates a good working knowledge of injection molding and industry best practices.

Who Should Consider Certification?

Anyone working in the plastics industry should consider Level 1 Certification for Injection Molding Professionals. Individuals and engineers can use this certification to improve their standing within the industry or their company. Molding Managers should consider offering this certification to train a strong workforce confident with a fundamental understanding of injection molding.

How to Get Certified:

Level 1 Injection Molding Professional certification testing is conducted either online or in person at a certified plastics testing center. The Level 1 certification requires the completion of a 3-part test taking approximately 1-2 hours to complete with a time limit of 3 hours total. The first portion of the test consists of a series of True-False questions to cover a broad spectrum of content. The second section of testing consists of multiple-choice questions designed to better differentiate a candidates understanding of common injection molding concepts. The third portion of the testing requires analysis of common molding scenarios designed to identify the candidate’s working knowledge of injection molding.

Once the participant has successfully completed the Level 1 certification test, they will be immediately provided with a printable certificate. If you are located within the region of a certified testing center such as the Americas or Southeast Asia, you will receive, via post, a wallet sized certificate as well as a full-sized certificate suitable for framing. You records will also be kept on our global database, so additional awards, plaques, and certificate copies can be ordered at any time in the future.

How to Prepare for Certification:

Although preparation training is not necessary to achieve certification, most injection molding professionals prepare for Level 1 Certification testing with 16-24 hours of our online training programs.

Testing Criteria:

- Working Safely in an Injection Molding Environment
- Identifying Machine Components and Their Function
- Comparing Basics of Hydraulic vs. Electric Machinery
- Understanding the General Purpose Screw
- Familiarity with General Polymer Types
- Amorphous vs. Semi-Crystalline Materials
- Thermoplastics vs. Thermosets
- Familiarity with the Molding Process, including: 1st Stage Injection, 2nd Stage Packing, Part Cooling, Screw Recovery and Part Removal
- Understand Basic Machine Controls
- Differentiating Modes of Operation
- Understanding Common Part Removal Techniques
- Knowledge of Common Visual Defects, including: Flash, Short Shots, Sinks & Voids, Jetting, Burning, Flow Lines, Weld & ---Meld Lines and Poor Surface Finish.
- General Hot Runner Systems
- Conventional Mold Bases
- General Material Characterization
- Basic Dimensions and Tolerances
- Understanding Material Handling
- Material Drying Methods
- Start-Up and Shut-Down
- General Material-Related Defects, including: Splay, Bubbles, & Blisters, Brittleness, Cracking & Crazing, Delamination, Contamination, and Poor Color Distribution
- Process Documentation Techniques
- Common Mold Machining Methods
- Conventional Gating Systems
- Typical Mold Maintenance Techniques
- Polymer Chain Orientation
- Basic Math and Common Calculations

31 Online Courses (25-44 hours + Study Guides, Certification, & Worksheets)

Typical Testing Time 1-2 hours