Introduction to Injection Molding (Brazilian Portuguese Version)

This course provides participants with a general introduction to the plastics industry. The primary focus of this training program is the day-to-day operations of a typical injection molding facility.

An Introduction to Injection Molding was created for newcomers to the injection molding industry or anyone that would like to learn more about plastics. We recommend that new hires take this course before participating in our Injection Molding Basics series.

• An overview of plastics and the industry
• A typical molding facility
• General plant safety
• An introduction to the molding process
• Molding machine components
• Material handling
• Injection mold terminology
• Common part defects

Injection Molding Basics (Brazilian Portuguese Version)

Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs.

These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.

Part 1: Machine

• Cites important safety precautions for working around injection molding machines
• Gives an introduction to the injection molding process
• Introduces machine types and the different modes of operation
• Discusses injection molding machine components and their respective functions
• General procedures for starting up and shutting down a molding machine

Part 2: Process

• Discusses polymers and the three criteria used to classify them
• Covers some of the more common procedures for material preparation
• Introduces the three phases of the molding process; injection, cooling and ejection
• Explains the need for maintaining an accurate process log
• Defines common injection molded part defects and explains their causes

Part 3: Mold

• Explains the specific functions that an injection mold must perform
• Introduces the various machining methods used to construct an injection mold
• Discusses the three mold configurations used in the industry
• Covers common runner shapes and gate types used in injection molds
• Gives an overview of proper injection mold maintenance

Understanding Plastics (Brazilian Portuguese Version)

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.

• The definition of plastics
• Polymer classification
• Material properties affected by processing
• Proper material handling techniques
• Processing characteristics of virgin and regrind

Establishing a Scientific Molding Process (Brazilian Portuguese Version)

This scientific molding training course provides participants with in-depth processing information to better prepare them for making appropriate and cost-effective decisions when establishing or improving a scientific injection molding process.

The course teaches a processing strategy that properly decouples 1st stage fill from 2nd stage pack. Students who understand and utilize the strategy described in this course will produce processes with a much higher repeatability. The steps outlined in this course are intended to quickly establish a scientific injection molding process, reduce downtime and improve process efficiency.

• General Rules for Scientific Processing
• Scientific Process Optimization Strategies:
  • 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

Scientific SkillSet™ Labs: Intermediate (Brazilian Portuguese Version)

Our intermediate Scientific SkillSet™ labs provide a unique and valuable learning experience for your setup technicians, processors, and engineers. Only from Routsis Training, these innovative courses combine detailed, step-by-step online instruction with practical hands-on labs and worksheets.

This exclusive training approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort and convenience of their own production environment. All our Scientific Skillset™ products are available in English, French, Spanish, Portuguese, Bahasa Malaysia, and Mandarin Chinese.

Each of the 13 course/worksheet combinations in this group focuses on developing an important processing-related skill — demonstrated on your production equipment.

Melt Temperature Measurement

It’s important for processors to understand that the temperature of the polymer melt will differ from the barrel temperature settings. The purpose of this lab is to determine the actual temperature of the polymer being injected into the mold. Participants practice taking accurate polymer measurements and documenting the results on their worksheet.

Mold Temperature Measurement

Mold coolant is used to help cool the polymer, allowing the part to be ejected without damage or distortion. It’s critical that techs remember the actual mold temperature may be different that the chiller setpoint. In this lab, participants use a surface temperature probe to determine the actual temperature of the coolant entering and leaving the mold.

Process Documentation

Machine-independent process documentation is an essential component of Scientific Molding. This approach to documentation promotes easy troubleshooting and allows the process to be duplicated — even when run on a different molding machine.

1^st Stage Injection Speed

Using a faster injection speed is an important step in optimizing the efficiency and consistency of the molding process. This lab teaches participants to quickly determine a fast injection speed that produces acceptable parts.

1^st Stage Injection Transfer

In order to accommodate normal variations in the material and processing conditions, the transfer position of the screw needs to be optimized. The purpose of this lab is to establish a 1st stage short shot between 90 and 95% of the final part weight, which is measured and documented on the participant’s worksheet.

1^st Stage Injection Pressure

It is important that your process always has adequate pressure available to ensure the machine can maintain the desired injection speed. The purpose of this lab is to determine the maximum injection pressure for your process, which will allow you to compensate for variations in the material and processing conditions.

1^st Stage Injection Time

It is important that your process has adequate time available. A correctly-set injection time ensures the screw can travel from the shot size to the transfer position. The purpose of this lab is to determine the fastest 1st stage injection time for your process, while compensating for normal variations.

1^st Stage Check Ring

In any Scientific Molding process, the check ring must be capable of providing a reliable, consistent amount of material during 1st stage fill. Participants evaluate and document the functionality of the check ring — to determine how consistently the molding machine is injecting material during 1st stage fill.

2^nd Stage Packing Pressure

The purpose of this lab is to determine the lowest and highest packing pressures that create an acceptable part, and then to determine a final packing pressure setting. Participants find the optimal packing pressure by examining the parts for sinks or flash — and logging their findings.

2^nd Stage Packing Time

Your process must have enough packing time to ensure the gate fully seals. In this lab, participants graph part vs. second stage weight — in order to determine the appropriate gate seal time for the process. Once determined, this value is used to derive the optimal second stage packing time.

2^nd Stage Final Cushion

For most processes, the optimal cushion is around 10% of the overall shot size. The purpose of this lab is to adjust the shot size and transfer position to create an optimal cushion at the end of 2nd stage packing. This prevent bottoming-out while maximizing pressure transfer.

2^nd Stage Clamp Force

Clamping must be set correctly in order to protect the mold and maximize the effectiveness of the mold vents. In this training lab, the participant determines the minimum amount of clamp force necessary to make an acceptable part, while compensating for normal process variations.

Screw Recovery Time

Optimal screw recovery protects the quality and integrity of your polymer during melting. In this lab, participants determine an appropriate recovery time — one that ensures the plastic material is not experiencing excessive shear, without wasting energy or time.

Scientific SkillSet™ Labs: Advanced (Brazilian Portuguese Version)

Designed for advanced process techs and engineers, our advanced Scientific SkillSet™ courses build on the skills developed in the intermediate labs. In these advanced, hands-on courses, participants learn how to quickly and effectively optimize a scientific injection molding process.

Each online video course/worksheet combination in this group builds an important processing-related skill. These skills are demonstrated on your production equipment — without costly seminars or the inconveniece of travel.

1^st Stage Fill Progression

In this lab, participants learn how the mold actually fills. Problem areas are identified and recorded on the lab worksheet. The participant performs a series of short shots to identify how the polymer flows through the gate, fills the cavity, and reaches the end of fill.

1^st Stage Rheology Curve

In-Mold Rheology allows you to gain extremely valuable rheological information about your mold and material without any special laboratory equipment. Participants determine an optimal 1st stage filing time for a given mold — by determining the injection time at which shear thinning occurs.

1^st Stage Cavity Imbalance

Mold filling imbalances contribute to unwanted variations in the molding process. The purpose of this test is to determine the injection speed that provides the optimal cavity filing balance.

Coolant Temperature

The purpose of this lab is to determine the lowest temperature which produces acceptable parts. Participants establish the optimal mold coolant temperature controller settings and log their results.

Cooling Time

In this SkillSet™ training lab, participants evaluate their process to determine an optimized cooling time, while compensating for normal variations in the molding process.

Rear Zone Temperature

Participants must determine a rear zone temperature that provides the best overall material conveyance during screw recovery. A correctly-set rear zone temperature conserves energy and maximizes the process’s melting capacity.

Mold Opening

Proper mold open settings minimize the distance the mold opens while safely increasing the mold open speed. In this lab, participants learn to configure both the speed and distance of mold opening — to optimize clamp settings while protecting part quality.

Part Ejection

Here, participants learn why part removal settings are essential to maintaining an efficient process. The goal of this exercise is to minimize the time and energy required to remove the part — while protecting both the part and mold.

Mold Closing

Proper mold close settings are essential to process optimization. In this course, participants learn to optimize the clamp settings while protecting the mold and actions.

Mold Protect Force

Proper mold protect settings are critical to both employee safety and mold welfare. In this exercise. participants learn to set the mold protect force correctly — to help prevent the mold from clamping on a stuck part and to reduce the potential for damage when ejection problems occur.

Comparative Rheology

Dealing with plastic material variation is inevitable in the injection molding industry. In this lab, participants learn how to analyze and quantify these variations — comparing materials, grades, lots, additives, temperatures, etc. and recording their findings.

Measuring Mold Deflection

Excessive mold deflection makes it difficult to establish and maintain a reliable injection molding process. This test determines the average mold deflection over a series of 5 cycles. The information they record in this lab is extremely useful for benchmarking and troubleshooting mold deflection issues.

Measuring Platen Deflection

Excessive platen deflection can make your processes unreliable. Here, participants learn how to benchmark and troubleshoot platen deflection issues on your facility’s injection molding machines.

Scientific Molding 101 (Brazilian Portuguese Version)

Scientific Molding 101 lays the foundational knowledge base necessary for the success of any injection molding employee.

This package provides employees with broad-based training on the injection molding machine, process, mold, plastics and Scientific Molding.

Anyone working with production equipment or handling the material will greatly benefit from this online training package, which is available in multiple languages.

Scientific Process Technician (Brazilian Portuguese Version)

Specifically designed to increase process technicians’ knowledge and skills, this training package contains both online courses and hands-on worksheets. Participants begin with the basics and progress to our Intermediate SkillSet™ labs.

Our Scientific Process Technician training package is available in English, French, Spanish, Portuguese, Mandarin Chinese, and Bahasa Malaysia.

Scientific Process Engineer (Brazilian Portuguese Version)

The online courses in this package are selected to lay the foundational knowledge base necessary for the success of any Scientific Molder.

Our unique Scientific SkillSet™ Labs allow you to practice and learn critical scientific molding skills used in developing and documenting a robust injection molding process.

Anyone involved in Process Development, Trials, Qualification, and Troubleshooting will benefit greatly from this package. The Scientific Process Engineer package is available in English, French, Spanish, Portuguese, Mandarin Chinese, and Bahasa Malaysia.