SmartTech™ Expert : Scientific Molding Training (4 Days)

This package gives participants an extended, well-rounded understanding of injection molding – with knowledge-based certification upon completion of the training. This 4-day course is perfect for anyone involved in process development, establishment, evaluation, optimization, or management.

SmartTech™ Expert provides the necessary knowledge and skills to build, document, troubleshoot, and optimize Scientific Molding processes. In addition, participants are well-equipped to pass the Injection Molders Professional Certification Exam, which is included with this package.

SmartTech™ Prerequisite Online Training

SmartTech™ Prerequisite Learning Objectives

  • Understand safety precautions around the molding machine
  • Introduces the 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
  • Basic material handling and drying techniques
  • Understanding number rounding, significant figures, and fractions
  • Mathematics skills training for class preparation
  • Understanding Scientific Molding parameters for:
    • 1st Stage Filling
    • 1st Stage to 2nd Stage Transfer
    • 2nd Stage Pack
    • Screw Delay
    • Screw Recovery
    • Screw Decompression
    • Cooling Time
    • Mold Opening
    • Part Ejection
    • Mold Closing
    • Clamping

SmartTech™ Day 1 : Classroom Discussion Topics

  • Safety
  • Inputs vs. Outputs
  • 1st Stage Injection
  • Practical Rheology
  • 1st Stage Cavity Imbalance
  • 1st Stage Check Ring Evaluation

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

Day 1 : SmartTech™ Day 1 : Skills & Learning Objectives

  • The importance of good housekeeping and machine safety
  • Machine guarding and personal protective equipment
  • 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
  • Difference between melt temperature and barrel temperature
  • Proper material temperature measurement techniques
  • Demonstrating the mold gating and filling patterns
  • Establishing a 90 to 95% 1st Stage fill based on part weight
  • Evaluation of the Check Ring performance during 1st Stage
  • Determine the degree of Imbalance during 1st Stage Injection
  • Identify the injection speeds which provide adequate shear thinning
  • Select the most efficient 1st Stage Injection Speed

SmartTech™ Day 2 : Classroom Discussion Topics

  • Rules of Processing
  • 2nd Stage Packing
  • Material Drying Technology
  • Process Control Systems
  • Determining Plastic Pressure

SmartTech™ Day 2 : Practical Skill Development

  • 2nd Stage Packing Pressure Optimization
  • 2nd Stage Packing Time Optimization
  • 2nd Stage Final Cushion Optimization
  • 2nd Stage Clamp Force Optimization
  • 1st Stage Check Ring Evaluation
  • 1st Stage Cavity Imbalance Study

SmartTech™ Day 2 : Skills & Learning Objectives

  • Understanding process parameters for 2nd Stage packing
  • Properly compensating for material shrinkage with pressure
  • Industry best practices for processing and troubleshooting
  • 5 rules of effective and efficient scientific processing
  • Effective 2nd Stage packing pressure establishment techniques
  • 2nd Stage packing time determination using part weight
  • Proper cushion sizing techniques to compensate for variation
  • Common hydraulic to plastic pressure conversion techniques
  • Proper machine independent process documentation techniques
  • Understanding closed loop process control systems
  • Uses for material drying including effective pre-heating techniques
  • Practicing proper techniques for determining optimal mold temperature
  • Determination of upper and lower acceptable packing pressures
  • Understanding all-electric molding machine control systems
  • Review of the difference between electric and hydraulic machine controls
  • 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
  • Determination of the clamping force for optimal venting

SmartTech™ Day 3 : Classroom Discussion Topics

  • Screw Recovery Optimization
  • Accurate Part Cooling
  • Process Documentation

SmartTech™ Day 3 : Practical Skill Development

  • Rear Zone Temperature Optimization
  • Screw Recovery Optimization
  • Coolant Temperature Optimization
  • Cooling Time Optimization
  • Scientific Molding Process Documentation

SmartTech™ Day 3 : 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
  • Presentation on how polymers get their strength and how it can be compromised
  • The effects of semi-crystallinity on shrinkage and part performance
  • Minimizing material degradation ad polymer chain breakdown
  • The effects of polymer chain orientation on performance and shrinkage
  • How hydrolysis causes increased polymer chain degradation
  • Difference between mold, coolant, and controller temperatures
  • Optimization of screw recovery efficiency through rear zone temperature
  • Practice setting of screw recovery to minimize material degradation
  • Performing effective machine independent process documentation
  • Optimal mold temperature determination techniques
  • Review of the steps to determine the most efficient cooling time
  • Performing a cooling time study to determine minimal cooling time
  • Calculating the optimal cooling time which compensates for variation
  • Effective machine independent process documentation techniques for:
    • 1st Stage Injection
    • 2nd Stage Packing
    • Part Cooling
    • Material Recovery
    • Mold Clamping

SmartTech™ Day 4 : Classroom Discussion Topics

  • Part Removal Optimization
  • Troubleshooting for Scientific Molders

SmartTech™ Day 4 : Practical Skill Development

Scientific Molding – Process Development & Documentation, using:

  • 1st Stage Injection Fill Progression
  • 1st Stage In Mold Rheology
  • 1st Stage Injection Transfer Optimization
  • 2nd Stage Packing Pressure Optimization
  • 2nd Stage Packing Time Optimization
  • 2nd Stage Final Cushion Optimization
  • 2nd Stage Clamp Force Optimization
  • Coolant Temperature Optimization
  • Cooling Time Optimization
  • Rear Zone Temperature Optimization
  • Screw Recovery Optimization
  • Part Removal Optimization

SmartTech™ Day 4 : Skills & Learning Objectives

  • Understanding the difference between hydraulic and plastic pressure
  • Common hydraulic to plastic pressure conversion techniques
  • 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
  • Machine independent coolant temperature measurement techniques
  • 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
  • Establish Scientific Molding Process Parameters for:
    • 1st Stage Filling
    • 1st Stage to 2nd Stage Transfer
    • 2nd Stage Pack
    • Screw Delay
    • Screw Recovery
    • Screw Decompression
    • Cooling Time
    • Mold Opening
    • Part Ejection
    • Mold Closing
    • Clamping

Post-Requisite Online Training

SmartTech™ Post-Requisite Learning Objectives

  • Review of applicable mathematics for the production floor
  • Understanding of formulas, decimals, and negative numbers
  • Proper use of a calculator to perform daily calculations
  • Understanding of common metric and imperial units
  • Calculating percentages, tolerances, and common equations
  • The 7 steps to the effective scientific troubleshooting in detail
  • Steps to establishing a Scientific Molding process
  • 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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4 Days of On-Site Skill Development & Professional Certification

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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.