Who is the course for

This course is designed for technical staff who already have a strong working knowledge of the injection moulding process and systematic troubleshooting techniques, but who wish to better understand, and increase their control of the moulding process to further improve part quality and consistency.

In order to enrol on this course, trainees must have already completed our Injection Moulding Module 2 programme

Learning Outcomes

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

• Work on their own to diagnose and eliminate all common moulding defects.
• Follow logical troubleshooting steps, using data from the moulding process including pressure curve data to analyse, find root cause and correct defects.
• Competently carry out full trials on new moulds, and optimise the moulding process for those new moulds using scientific moulding principles
• Understand the tools and terminology used in relation to process capability studies and how to use the data gathered during those studies (Cp, Cpk, standard deviation, mean, range etc.)
• Fully understand the different handling and processing requirements for various thermoplastic materials
• Know where to access material specifications and supplier processing guidelines and know how to interpret this information
• Check the suitability of a mould to fit and run in a given machine

Content

• Recap on prior learning from Module 2
• Review of plastic materials knowledge-crystalline and amorphous materials, shrinkage, warpage, dimensional control, etc.
• Troubleshooting common moulding defects using software simulation and practical machine sessions
• Introduction to SPC (Standard deviation, range, mean, Cp, Cpk). How to calculate Cp/Cpk and interpretation of results
• Introduction to Scientific Moulding. Practical sessions using scientific moulding principals to optimise the process
• Optimising machine cycle time.
• Setting SPC monitoring and machine alarms
• Machine “cold start-up” practical session. Observing impact on part dimensions and weight, as well as process pressures and process monitoring statistics

As with Module 2, much of the course time is spent in practical sessions – working directly on two or more moulding machines, with different moulds and materials. A number of case studies are used to aid the learning process.

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.