Injection Moulding Module 1

Dates: 23rd September, 2019 - 26th September, 2019 (4 days)
25th November, 2019 - 28th November, 2019 (4 days)

Duration: 4 days

Location: 7 Centre Court, Blyry Business and Commercial Park, Athlone.

Accreditation: Injection Moulding Machine Setting

Full Fee: €1495 including course manual, certification, lunch and refreshments

Course code: 5N3035

Programme overview

This course is a troubleshooting course. It is suitable for Operators/ Technicians/ Supervisors/ Engineers with at least a few months of moulding experience or having completed the Module 1 course or similar.

It starts by covering the cycle with an in-depth review of each of the parameters making up the stages in the cycle. Theory sessions (2 hours each, one per day) include Parameters and their control, Setting up a mould with no setting sheet (7 point plan), Plastic Materials, Mould Design and Troubleshooting – with a major emphasis on troubleshooting during all sessions.

The remainder of the course is practical, setting up moulds from scratch, selecting pressures, speeds, times and strokes before building the shot up and dealing with defects as they arise. We concentrate on understanding the process with an in-depth explanation of what is happening to the material and the many ways the defect can be avoided. Using injection/ holding profiles is covered in the theory sessions and practiced on a hard-to-fill and poorly vented training mould.

A major benefit of the course is the restriction in numbers to ensure hands-on experience, and we also cover a lot of theory informally during the practical sessions.

Where possible we restrict Injection Moulding course numbers to just six places using up to four machines.

Safety Shoes – Required on this course

We can deliver a shorter tailored programme at our centre in Athlone for you/ or on-site if you have injection moulding capability there.



Course Content

Good Moulding Shop Practice
Pressure curves – the inside view of what is going on during moulding
Analysis of the Moulding Cycle – explaining the various parameters using everyday analogies
Basic Machine Set Up from a blank programme – the Clamp Unit and Injection Unit
Basic Machine Optimisation

Machine Safety Features
Lifting Equipment
Safety for Moulds
Safe Operation Procedures

Practical Exercises:
Mould Removal
Mould Placement including mould safety setup, ejectors, setting clamping parameters
Setting Injection Unit Parameters

Analysis of Basic Moulding Faults (short shot, flash, mould safety)
Lots of practice fixing part defects, and developing a logical troubleshooting method

Who should attend

This course is aimed at anyone who wants to get a very comprehensive understanding of the injection moulding process.  The course material has a very practical application with approximately 70% of the time spent on the machines. No prior experience is assumed but all trainees will be expected to complete our free e-learning module in advance of attending training.

But if you are:

•  are working in a quality or R&D role. 
•  do not have injection moulding at your site and are supplied externally with moulded parts
•  Or you just don’t want/ need to learn about the operation of a moulding machine as this is not relevant to your job,but you do want to learn about moulded part defects and troubleshooting these issues.
If so then please contact us directly and we can deliver a shorter tailored programme at our centre in Athlone for you/ or on site if you have injection moulding capability there.

Learning outcomes

At the end of the course trainees should be able to:

  1. Describe the safety hazards in the moulding production environment
  2. List the steps in a moulding cycle in the correct order
  3. Describe the function of each stage in the moulding cycle
  4. Explain mould terms such as draft angle, parting lines, the sprue, runner, gate, mould vents.
  5. Install an injection mould into a moulding machine
  6. Remove an injection mould from a moulding machine
  7. Demonstrate how to set up mould cooling pipes to ensure even flow of cooling water around a mould.
  8. Select appropriate injection unit nozzle diameter/ radius to match a new mould’s sure bush diameter and radius
  9. Set up mould opening and closing/ clamping speeds, pressures and distances from a blank programme
  10. Set up ejection forward and reverse speed, pressure and distances from a blank programme
  11. Set up the injection, holding, plasticising and decompression settings from a blank programme.
  12. Start up a moulding machine and adjust the shot size/ holding pressure to produce cosmetically acceptable parts
  13. Purge out the screw and barrel and shut down a moulding machine
  14. Re-start a moulding machine after an interruption such as an emergency stop being pressed or guard door being opened
  15. Describe the root cause of basic troubleshooting defects – Flash, Burn Marks, Short Shots, Sink Marks, Weld Lines.

Trainer Profile

Steve O’ Leary has delivered training in Injection Moulding for First Polymer Training since 2000, initially joining FPT Skillnet as the Training Center Manager. Previous to this he worked as an Extrusion/ Injection Moulding Engineer with Boston Scientific in Galway, Extrusion Technician and Extrusion Supervisor with Sherwood Medical in Tullamore (currently Medtronic Tullamore) and as an Injection Moulding Technician with Tubex in Nenagh, Co. Tipperary. He graduated from Athlone IT having studied Plastics Engineering from 1988 to 1992.

Find out how to achieve a Major Award in Injection Moulding (Level 5)

This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications – see  and is a mandatory component of major award 5M3080 – Plastics Injection Moulding.

 Protection for Enrolled Learners Policy

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