SmartTech™ Essential : Scientific Molding Training (2 Days)

This package provides participants with a well-rounded understanding of Scientific Injection Molding. SmartTech™ Essential is perfect for die setters, technicians, engineers, or anyone acting in a management or supervisory role.

This course is focused on the necessary information and skills to build, document, and troubleshoot a Scientific Molding process.

SmartTech™ Prerequisite Online Training

SmartTech™ Prerequisite Learning Objectives

  • Understand safety precautions around the molding machine
  • Basic knowledge of the injection molding machine, process, mold, & material
  • Identify machine components and understand their functions
  • General injection molding machine startup and shutdown
  • Common polymers types and their general classifications
  • Understand the purpose and importance of a process log
  • Visual injection molding defects and their typical causes
  • Identifying basic injection mold components and functions
  • Hot and cold runners systems and common gating methods
  • Basic injection mold maintenance during production
  • Material properties which are affected by processing

SmartTech™ Day 1 : Classroom Discussion Topics

  • Safety
  • Inputs vs. Outputs
  • 1st Stage Injection
  • 2nd Stage Packing

SmartTech™ Day 1 : Practical Skill Development

  • Melt Temperature Measurement
  • 1st Stage Injection Fill Progression
  • 1st Stage Injection Speed Optimization
  • 1st Stage Injection Transfer Optimization
  • Maximum 1st Stage Injection Pressure
  • Maximum 1st Stage Injection Time
  • 1st Stage In-Mold Rheology

SmartTech™ Day 1 : Skills & Learning Objectives

  • The importance of good housekeeping and machine safety
  • Machine guarding and personal protective equipment
  • Industry best practices for processing and troubleshooting
  • 5 rules of effective and efficient scientific processing
  • Understanding process parameters for 1st Stage injection
  • Basic optimization of 1st Stage injection and transfer
  • Fundamental scientific (DII or short shot molding) methodology
  • Proper setting of maximum 1st Stage injection pressure
  • Correct and incorrect uses of injection velocity profiling
  • Transferring 1st Stage injection to 2nd Stage pressure by weight
  • Understanding process parameters for 2nd Stage packing
  • Properly compensating for material shrinkage with pressure
  • Effective 2nd Stage packing pressure establishment techniques
  • 2nd Stage packing time determination using part weight
  • Proper cushion sizing techniques to compensate for variation
  • Establishing a 90 to 95% 1st Stage fill based on part weight
  • Determination of upper and lower acceptable packing pressures
  • Optimization of final packing pressure to compensate for variation
  • Practical gate seal time determine techniques
  • Manual graphing of part weight vs. 2nd Stage packing time
  • Selection of optimal 2nd Stage packing time for variation compensation
  • Techniques for obtaining the optimal final cushion sizing
  • Adjustments to shot size and transfer position for proper cushion sizing

SmartTech™ Day 2 : Classroom Discussion Topics

  • Screw Recovery Basics
  • Part Cooling Basics
  • Scientific Molding Process Documentation
  • Introduction to Troubleshooting

SmartTech™ Day 2 : Practical Skill Development

  • Mold Temperature Measurement
  • 2nd Stage Packing Pressure Optimization
  • 2nd Stage Packing Time Optimization
  • 2nd Stage Final Cushion Optimization
  • 2nd Stage Clamp Force Optimization
  • Process Documentation

SmartTech™ Day 2 : Skills & Learning Objectives

  • Understanding process parameters for screw recovery
  • Screw decompression both before & after screw recovery
  • Minimizing the stresses imposed on the material
  • How to reduce screw flex and breakage during recovery
  • Reduction of energy consumption during shot generation
  • Proper uses for back pressure during screw recovery
  • Melt and mold temperature measurement technique review
  • Proper melt temperature matching troubleshooting techniques
  • Difference between mold, coolant, and controller temperatures
  • Optimal mold temperature determination techniques
  • Review of the steps to determine the most efficient cooling time
  • Proper machine independent process documentation techniques
  • Effective machine independent process documentation techniques for:
    • 1st Stage Injection
    • 2nd Stage Packing
    • Part Cooling
    • Material Recovery
    • Mold Clamping
  • The definition and role of a scientific troubleshooter
  • Scientific vs. non-scientific process documentation techniques
  • The difference between conventional and scientific troubleshooting
  • An introduction to proper scientific troubleshooting techniques
  • The 7 steps to the effective scientific troubleshooting
  • The role of scientific documentation in proper documentation
  • Performing effective machine independent process documentation

SmartTech™ Post-Requisite Online Training

SmartTech™ Post-Requisite Learning Objectives

  • Material properties which are affected by processing
  • Basic material handling and drying techniques
  • How hydrolysis causes increased polymer chain degradation
  • Uses for material drying including effective pre-heating techniques
  • Basic operation of hot air, compressed air, desiccant, and vacuum dryer systems
  • Different methods for removing both absorbed and surface moisture
  • Explanation of drying concepts including relative humidity and dewpoint
  • Effective and reliable portable dewpoint measurement techniques
  • Using proper process documentation to your advantage
  • Identification, causes, and effective troubleshooting techniques for fixing:
    • Flash
    • Sinks & Voids
    • Short Shots
    • Jetting
    • Gate Blush
    • Burning
    • Flow Lines
    • Weld & Meld Lines
    • Poor Surface Finish
    • Large Parts
    • Differential Part Dimensions
    • Part Warpage
    • Splay, Bubbles, & Blisters
    • Brittleness, Cracking, & Crazing
    • Delamination
    • Contamination
    • Poor Color Distribution
    • Part Sticking & Ejector Pin Marks
    • Occasional Part Hang-Up

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2 Days of On-Site Skill Development

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†  The prices listed here are for an individual (1 seat). Substantial discounts are available for groups. Many of these seminars also have an optional on-machine workshop available for an additional fee. All prices are listed in U.S. Dollars (USD). Prices are provided for reference purposes only and are subject to change without notice.