Introduction to Injection Molding (Spanish 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 (Spanish 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 (Spanish 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 (Spanish 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

Process Documentation for Scientific Molders (Spanish Version)

This training program will provide participants with a better understanding of proper documentation and the procedures associated with documenting a scientific molding process.

The comprehensive course teaches the differences between machine-dependent and machine-independent process parameters as well as the importance of proper documentation for each. Students will also learn the necessary procedures associated with documenting and maintaining a robust scientific injection molding process.

• Definition of Scientific Process Documentation
• Inputs vs. Outputs
• Machine-Dependent Documentation
• Machine-Independent Process Documentation
• Documenting Barrel & Recovery
• Documenting 1st Stage Injection
• Documenting 2nd Stage Packing
• Documenting Part Cooling
• Documenting Mold Clamping
• Hybrid Machine & Process Documentation
• Documenting All Process Changes

Processing Parameters for Scientific Molding (Spanish Version)

This 3-part training program will provide participants with a better understanding of the parameters involved with a scientific injection molding process and the control panels of injection molding machines.

This course is beneficial to die setters, process technicians, maintenance personnel, engineers, and anyone else using the control panel.

Part 1 - Introduction

• Scientific Molding Overview
• 5 General Rules for Scientific Molding
• Understanding the Process Controller
• Common Units for Process Parameters

Part 2 - Process

• Process Inputs versus Process Outputs
• 1st Stage Injection Inputs and Outputs
• 2nd Stage Packing Inputs and Outputs
• Cooling Inputs and Outputs
• Screw Recovery Inputs and Outputs
• Other Commonly Found Process Inputs

Part 3 - Part Removal

• Mold Open Settings
• Part Ejection Settings
• Core Pull Settings
• Mold Closing Settings

Injection Mold Setup (Spanish Version)

This comprehensive 2-part program provides participants with a better understanding of die setting including safety preparation, documentation, mold removal & installation, and process startup. This is an excellent course for anyone involved in die setting including process technicians and supervisors.

Injection Mold Setup, Program 1

• Safety Concerns and Considerations for Die Setters
• Injection Mold Setup Scheduling and Preparation
• Machine Dependent and Independent Documentation
• Proper Injection Mold Preparation and Examination
• Safe and Effective Mold Removal Techniques

Injection Mold Setup, Program 2

• Safe and Effective Mold Installation Techniques
• Setting Clamp Tonnage and Mold Protect
• Optimizing Clamp and Part Ejection Settings
• Establishing Consistent Screw Recovery
• Melt Temperature Matching Techniques
• Process Startup and Scientific Molding Principles

Material Drying Technology (Spanish Version)

Routsis Training’s two Material Drying Technology online courses provide participants with a better understanding of how different polymers are best dried and prepared for reliable processing. These courses show participants how proper plastics material handling and drying is critical to produce a consistent product and process. Course One reviews polymer basics, as well as both hygroscopic and non-hygroscopic polymers – to better convey the importance of properly drying water-sensitive materials.

Material Drying Technology, Course 1

• Polymer Basics
• Hygroscopic vs. Non-Hygroscopic Polymers
• Hydrolysis
• Purposes of Drying
• Dewpoint
• Dewpoint Measurement
• Dewpoint Sensors
• Drying Procedures

Material Drying Technology, Course 2

• Hot Air Dryers
• Compressed Air Dryers
• Desiccant Dryers
• Vacuum Dyers
• Calculating Material Consumption
• Calculating Residence Time
• Calculating Dryer Capacity

Automation & Robotics for Scientific Molding (Spanish Version)

These training programs will provide participants with a better understanding of how automation and robotics are used to streamline production within the injection molding industry.

Part 1

This training program will provide participants with a better understanding of the different options and capabilities associated with automation.

• Guarding and Safety Considerations
• Types of Automation Used for Injection Molding

Part 2

This training program will provide participants with a better understanding of the different options and capabilities associated with robotics.

• Controllers and Movements of Robotics
• End-of-Arm Tooling
• Sprue Pickers
• Top-Entry Robots
• Side-Entry Robots
• Articulating Robots
• Examples of Robotics

Electric Injection Molding (Spanish Version)

Our two Electric Injection Molding courses will provide participants with a better understanding of the benefits and capabilities of modern all-electric injection molding machines. Safety concerns particular to electric molding machines are also covered.

1: Understanding Electric Injection Molding Machines

This training program will provide participants with a better understanding of how electric injection molding machines function – as well as the many benefits and capabilities associated with electric molding machines.

• General Injection Molding Safety
• Electric Molding Machine Safety
• Machine Guarding
• Comparing Hydraulic and Electric Machines
• Basic Molding Machine Functions
• Efficiency, Accuracy and Repeatability
• Alternative Machine Designs
• Typical Uses for Electric Injection Molding Machines

2: Processing with Electric Injection Molding Machines

Packed with in-depth processing information, this course will undoubtedly prepare processors for making more appropriate and cost-effective decisions. Participants will also learn how to optimize any process that’s running on an electric injection molding machine.

• Closed-Loop Process Controls
• Hydraulic vs. Electric Molding Machine Controls
• 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

Math for Molders (Spanish Version)

This two-part training program was created for all personnel within the injection molding industry who would like to expand or fine-tune their math skills.

These courses will greatly benefit any participant of RJG’s classroom-based Master Molder ^SM Certification Series either as a primer or as follow-up training.

Part 1

• Whole Numbers, Negative Numbers and Decimals
• Using a Calculator
• Addition, Subtraction, Multiplication and Division
• Rounding Numbers and Significant Figures
• Formulas, Equations and Order of Operations

Part 2

• Metric and Imperial Units
• Length and Distance
• Area, Volume & Flow
• Weight, Mass and Force
• Conversions
• Understanding Percentages
• Calculating Plastic Pressure and Part Shrinkage
• Calculating Tolerances

Scientific Troubleshooting for Injection Molders (Spanish Version)

These four in-depth scientific molding training programs provide participants with the knowledge base required to identify and troubleshoot over twenty-five of the most common injection molded part defects. Users will also come away with a better understanding of how to best process, document and maintain a reliable scientific injection molding process.

Introduction

This scientific molding training program focuses on the 7-step process to scientific troubleshooting. Participants are also presented with information and practices on how to best process, document and maintain a reliable scientific injection molding process.

• Step 1 – Develop a Scientific Molding Process
• Step 2 – Properly Document the Process Outputs
• Step 3 – Examine the Defective Part and Rule Out Obvious Causes
• Step 4 – Compare the Current Process with the Documented Process
• Step 5 – Return the Process to the Documented Standard
• Step 6 – Verify the Part and Process
• Step 7 – Document all Changes Made

Visual Defects

Nine of the most common visual defects encountered in injection molding processing are covered within this extensive scientific molding training program. Participants will be better prepared to troubleshoot these defects as each one will be defined and their respective causes and corrections will be explained in detail. Defects include:

• Flash
• Sinks and Voids
• Short Shots
• Jetting
• Gate Blush
• Burning
• Flow Lines
• Weld and Meld Lines
• Poor Surface Finish

Dimensional Defects

This scientific injection molding training program will provide participants with a better understanding of how to best troubleshoot five (5) of the most common dimensional defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. These dimensional defects include:

• Large Parts
• Small Parts
• Larger Parts at the Gate
• Smaller Parts at the Gate
• Warpage

Material and Cycle-Related Defects

After completing this scientific molding training program, participants will have a better understanding of how to best identify and troubleshoot many of the most common Material and Cycle-Related defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. The material and cycle-related defects discussed in this course include:

• Splay, Bubbles, and Blisters
• Brittleness, Cracking, and Crazing
• Delamination
• Contamination
• Poor Color Distribution
• Part Sticking and Ejector Pin Marks
• Occasional Part Hang-Up

Purging for Scientific Molders: Intermediate (Spanish Version)

Designed specifically for injection molders, Routsis Training’s intermediate-level purging courses introduce a scientific approach to material purging.

These courses discuss important purging concepts and detail common procedures for purging plastic material from the injection screw, barrel, and nozzle — and techniques for cleaning hot runner systems and gate drops.

Purging Techniques

• Definition of Purging
• General Injection Molding Safety
• Injection Molding Machine Safety
• Plastic Purging Safety
• The Purpose of Purging
• Small and Large Shot Purging
• Continuous and Closed-Mold Purging
• Dry and Wet Purging
• Purging Heat Sensitive Materials
• Purging High Temperature Materials
• Hot Runner and Gate Drop Cleaning
• Nozzle and Screw Removal

Purging Procedures

• Phase 1: Preparation
• Phase 2: Initial Purging
• Phase 3: Final Purging
• Phase 4: Production

Injection Mold Maintenance (Spanish Version)

This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life and increase its productivity.

• Proper mold maintenance
• Mold storage and preparation
• Water line maintenance
• Techniques for extending tool life

Scientific SkillSet™ Labs: Intermediate (Spanish 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 (Spanish 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.

The 5S System (Spanish Version)

5S is a critical component of Lean Manufacturing. The 5S system is used by successful manufacturing facilities worldwide. It consists of 5 simple and concise steps – Sorting, Straightening, Sweeping, Standardizing, and Sustaining – that can help your facility reduce clutter and waste and, ultimately, increase efficiency and productivity.

Production SkillSet™

Our online 5S training courses are built on Routsis Training’s exclusive SkillSet™ model. These courses combine clear online training videos and hands-on worksheets. This approach allows companies to perform the same type of classroom learning found in popular seminars in the comfort of their own production environment.

Each unique training course is a blend of the following components:

• BACKGROUND:
  Your technicians understand the goal of each Production SkillSet™
• PURPOSE:
  Technicians learn specifically how each Production SkillSet™ applies to their job
• EQUIPMENT:
  Items are detailed to ensure techs have the tools they need to succeed
• PROCEDURE:
  Each step is demonstrated so your techs can proceed with confidence
• WORKSHEET:
  Contains all the information your techs need to succeed with each SkillSet™

Step 1: Sorting

In the 5S System, the Sorting step’s goal is to eliminate all unnecessary items from the immediate workplace. This is done by sorting the workplace to determine what to keep, what to toss, and what to store. This helps prevent clutter from interfering with everyday production activities.

Step 2: Straightening

At the end of the Straightening step, everything in the workplace is neatly organized; resulting in a more convenient and more efficient workplace.

Step 3: Sweeping

In the Sweeping step, the best method for cleaning each selected area in the workplace is determined. A reasonable cleaning schedule should also be determined to ensure the workplace remains efficient, clean and organized.

Step 4: Standardizing

The goal of the Standardizing step is to achieve consistency. A similar appearance and layout should be applied to all workstations whenever possible. This step is often performed after a similar workplace or area within the plant has already been straightened.

Step 5: Sustaining

The purpose of the Sustaining step is maintenance. This is achieved by a review of the workplace and the existing Sorting and Straightening documentation – to ensure the workplace is efficient and up-to-date. This helps identify necessary materials or equipment that have been added to the workplace but have not yet been incorporated into the 5S documentation.

Scientific Molding 101 (Spanish 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 Molding 102 (Spanish Version)

Scientific Molding 102 builds on the knowledge base established in Scientific Molding 101.

This online plastics training package provides a great wealth of information to augment the knowledge of any processor, technician, or die setter.

Scientific Process Technician (Spanish 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 (Spanish 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.

Scientific Troubleshooter (Spanish Version)

Our Scientific Molding Troubleshooter training package is designed to make you an expert technician. By providing access to our more advanced scientific molding and technical courses, users will gain a better understanding of how to establish, document and maintain a reliable scientific injection molding process.

You’ll learn the steps required to establish a robust and repeatable scientific injection molding process. Next, we perform an in-depth examination of process parameters and the control panels of injection molding machines. Proper process documentation — a critical aspect of Scientific Molding — is also covered in detail.

These courses also provide you with the knowledge required to identify and troubleshoot over 25 of the most common molded part defects.

Injection Mold Setter Certification (Spanish Version)

Perfect for die setters and others involved in mold changes, including setup and process technicians, the online courses in this training package provide the perfect preparation for the Injection Mold Setter Certification Exam, which is included in the package. Courses include basic injection molding, mold setup, process establishment and troubleshooting.

Injection Molding Professional Certification (Spanish Version)

The online courses and labs in this training package are the perfect way to prepare for the Injection Molding Professional Certification Exam, which is included.

In order to attain certification, candidates must demonstrate a working knowledge of injection molding safety, machinery, processing, tooling, materials, and quality — and demonstrate a solid understanding of current industry best practices. These concepts are covered in detail throughout the courses in this package.

The Injection Molding Professional Certification Package is ideal for technicians, supervisors, engineers, and managers.