Injection Moulding Module 2

Dates: 9th November, 2020 - 12th November, 2020 (4 days)

Duration: 4 days

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

Accreditation: Injection Moulding Process Optimisation

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

Course code: 5N3036

Programme overview

This course is a troubleshooting course. It is suitable for Operators/ Technicians/ Supervisors/ Engineers with at least a few months 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.



Who is the course for

This course builds on the content covered in our Injection  Moulding  Module 1 programme and so is aimed at those who have already completed Module 1, who wish to develop their troubleshooting skills.  Candidates who have extensive injection moulding experience may be able to attend this course without completing Module 1, ‘if’ they have otherwise gained the knowledge and are able to:

  1. List the steps in the injection moulding cycle
  2. List the parameters that make up the moulding cycle and explain what these parameters do

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

  1. Explain in detail what happens during a full injection moulding cycle from start to finish
  2. Describe the logical troubleshooting steps to take to fix Flash, Burn Marks, Short Shots, Sink Marks, Weld Lines, Voids, Bubbles, Jetting, Surface drag marks, Splay.
  3. Demonstrate the logical troubleshooting steps to take to fix Flash, Burn Marks, Short Shots, Sink Marks, Weld Lines.
  4. List the positive and negative effects of increasing and decreasing the main injection moulding parameters – Shot Size, Switchover Position, Injection Speed, Injection Pressure, Injection Time, Holding Pressure, Holding Time, Back Pressure, RPM Speed, Decompression Distance, Decompression Speed.
  5. List the main part design recommendations for plastic parts.
  6. Explain the main difference between Thermoplastic and Thermoset materials.
  7. Describe the main difference in polymer chain structure of Amorphous vs Crystalline plastic materials
  8. Briefly explain how the differences between Amorphous and Crystalline material structures affects the mechanical and flow properties of the materials.
  9. Explain what is shown on injection speed/ pressure/ stroke curves during the injection, holding, plasticising and decompression stages.
  10. Set up and optimise injection speed profiles to minimise the actual injection time and switchover pressure.
  11. Set up and optimise holding pressure profiles to minimise sink marks and flash
  12. Describe what the term melt cushion means, what it is used for and how various injection unit settings affect it.
  13. Demonstrate how to adjust the shot size and switchover position to change the melt cushion value without affecting the parts being produced.


Good Moulding
Shop Practice and Safe Operating Procedures
Analysis of the Moulding Cycle
Practical Session
Basic Machine Set Up
Clamp Unit
Injection Unit
Basic Machine Optimisation
Practical Demonstrations

Design and Construction
Cooling Venting
Requirements/Part Design

Plastics Materials:
Processing of various thermoplastics
Correct material handling & preparation
Processing factors relating to thermoplastic materials

Process Control:
Process variables & how they influence part quality/product consistency
Selection of correct process parameters
Screw speed optimisation
Material and mould temperature selection
Profile injection speed
Holding pressure optimisation
Influence of one processing variable change on other variables
Practical session on machine
Optimisation of the moulding process
Setting for consistency
Practical optimisation of the moulding machine

Analysis of mould faults
Logical troubleshooting
Practical examples


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.

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