Seminar Outline
- Introduction & Overview
- Purpose
- Perspectives on the plastics' industry, manufacturing
- Profits
- What is your product
- The components of a successful plastic's application
- Concurrent engineering and its benefits
- The four molding variables
- Machine conditions vs. Plastic conditions
- Processing Guidelines
- Starting off True North
- Five Plastic Variables
- Machine vs. Plastic conditions
- Detailed Process optimization at the press
- Common Molding Problems: Causes and Solutions; Class Picks Topics!
- Splay
- Color streaking, swirls, marbling
- Bubbles in clear parts
- Pin (ejector) push marks, see also parts sticking
- Shorts, sinks, record grooves or waves
- Flash
- Warp/Dimensional Stability
- Burns
- Black Specks
- Worm Tracks or Jetting
- Brittleness
- Contamination
- Delamination
- Weldlines
- Poor living hinge life
- Gate Blush
- Gloss, and gloss gradients
- Hot Runner issues
- Infrared Thermography
- Plus any topic of your choice
Seminar Outline
- Introduction
- Purpose
- Perspectives on the plastics' industry, Injection Molding
- Profits
- The five components of a successful plastics' application
- Concurrent engineering and its benefits
- History and Trends
- You want it when?
- Polymer Basics and Resin Selection
- Where plastics originate
- Chain length and molecular weight distribution
- Melt Flow Rate testing
- Moisture Sensitive Polymers
- Degradation
- Use of regrind
- Plastic Categories
- Thermoset LSR
- Thermoplastic
- Amorphous vs. Semi-crystalline plastics
- Crystallinity
- Mold shrinkage
- Degree of Crystallinity
- Additives
- Warp
- Material selection and Testing; a designer's guide
- Questions that must be answered
- Properties to watch during the selection process
- What the physical tests will tell you
- Single point data vs. curves
- Polymer Testing
- Selected physical property tests
- Comparing data sheets
- Glenn Beall's check list
- Overview of Injection Molding Processing
- Machine Components
- How the machine works
- Hydraulic
- Electric
- What is important for the Designer, Mold Maker: mold opening
- Processing
- Plastic flow
- Multi-cavity flow
- Press issues
- Identical Parts over Time/Shipments/States/Countries
- Process Parameters You Need to Watch, run to run; different presses; identical part
- Mold/Tool Design/components
- Tool Design
- Mold Components
- Hot vs. Cold Runner
- Multicavity Molds
- Gating
- Hot tips
- Runners Sizing
- Mold-filling analysis
- Accuracy of CAD model/Resin data, no general comments
- Full CAD model, all the details
- Accuracy of Resin data
- Example with benefits and issues
- Venting
- Silicone molds
- Offshore Manufacturing (on request only)
- Reasons to locate offshore
- Reasons not to move offshore
- Approaches to offshore manufacturing
- Proactive check-ups
- Additional thoughts
- Piece Part Design: The Plastics Perspective (It is not nice to fool with Mother Nature)
- Components of Design
- Nominal Wall
- Projections
- Depressions/Holes
- Uniform Nominal Wall
- Shrinkage, Amorphous vs. Semi-Crystalline
- Changes in nominal wall
- Radii
- Dimensional Stability - Cooling and Warp
- Nominal wall transition/junction/radius
- Filling pattern
- Joining flat plates
- Radius
- Warp
- Draft
- Polish/Texture
- Case Histories
- Projections
- Ribs
- Bosses
- Gussets
- Flow considerations
- Sink/shrink cosmetics
- Venting
- Depressions/Holes
- Blind Holes
- Through Holes
- Venting
- Fasteners
- How to form, tooling issues
- Weldlines
- Filling/Flow considertions
- Stress Management
- Bealls 13 Rules
- Tolerances
- Components of Design
- Hinges and Snap Joint Techniques
- Flexible design techniques
- Distortion snaps
- Press-fit assembly
- Snap-fits, snap-hook designs, cantilever snap joints, annular snap-joints, latches, permanent snap design and twist snaps.
- Miscellaneous
- Instructors information
- Resources
- Checklists
- Essential information to be agreed upon by product designed and mold designer
- Test your knowledge of plastic part design
Seminar Outline
- Introduction: The Strategy
- Purpose
- Perspectives on the plastics' industry, Manufacturing
- Staying Competitive
- Key components of a successful validation/plastics application
- Concurrent engineering and its benefits
- Organizing the hundreds of variables in processing/parts; four categories
- Machine conditions vs. Plastic conditions
- Validation Strategy
- Case History
- Piece Part Design Overview, You cannot violate laws of nature!
- Components of Design
- The "Golden Rule" for nominal wall
- Shrinkage, Amorphous vs. Semi-Crystalline
- Cooling and Warp
- Draft
- Venting
- Gating with respect to weldlines
- Polymer Overview
- Polymer Basics, making and breaking polymer chains
- Moisture Sensitivity relative to performance
- Critical for success
- Costs for replacement
- What data sheets tell you
- Single point data
- IQ (Installation Qualification)
- Medical Device Quality Systems Manual Reprints
- Check List
- Mold/Tooling Requirements
- Machine Calibrations
- Machine Function (Machine Audit)
- Clean room requirements
- OQ (Operational Qualification; Establish a Process, Document and Define Ranges/Window; Starting with a Pre-run or Baseline Process)
- Step 1: Optimizing First Stage: Plastic Flow Rate
- How plastic flows, viscosity
- Viscosity curve
- Viscosity vs. temperature, lot variations and injection rate
- Flow balance
- Cruise Control on injection molding machines
- Two stage molding
- Case history
- Non-return valve (check ring) and nozzles
- Nozzle tips
- Step 2: Optimizing Second Stage: Plastic Pressure
- Basic hydraulics
- Hydraulic Pressure vs. Melt Pressure
- Back Pressure
- Intensification Ratio
- Pressure Loss
- Gate seal vs. unseal
- Pressure vs. time graphs
- Clamp force
- Platen wrap
- Pressure Loss Documentation
- Step 3: Cooling Rate and Time
- Percent of Cycle
- Turbulent Flow
- Series vs. parallel circuits
- Cooling issues
- Infrared Thermography
- Cycle time optimization studies
- Step 4: Plastic Temperature
- The hopper
- Drying
- The feed throat
- Barrel vs. melt temperatures
- Screw components and design
- How plastics melt
- Back pressure
- Screw problems
- How to measure temperature
- Step 5: Challenge the Process
- When to start saving parts
- Force viscosity variations
- Different resins?
- Capability studies
- Step 6: Test the part; expect issues to develop
- Test Conditions
- Thermocycle
- Environment
- Metrology
- First article inspections (FAI's)
- Visual inspections
- Do the DOE's Necessary/Correctly
- What are the issues, problem(s) clearly defined?
- List factors
- Possible factors
- Recommendations
- Factors with respect to four plastic categories
- Do we know the response for any of these factors
- Select Factors (variables)
- Machine "Set Points" vs. "Plastic Conditions"
- DOE check list
- Screening DOW's to establish process window
- Documentation
- Set up sheet per machine
- Universal Set up sheet, mold specific
- Process Monitoring Recommendations
- First tier
- Second tier
- Step 1: Optimizing First Stage: Plastic Flow Rate
- PQ (Process Performance Qualification; Test production performance of the process under "production" conditions)
- Run established process for production, time 4 - 24 hours
- Lot variations
- Different Processors
- Shift changes
- Run on different machines
- Verify output, Dimensions, function, capability, scrap etc.
- Document corrective action and confirm
- Evaluate entire system, molding, secondary operations, labels, and document results
- Implement corrective actions
- Document process/equipment changes
- Process monitoring variables
- Obtain customer approval
- Run established process for production, time 4 - 24 hours
- Miscellaneous
- Universal Setup Sheet
- Optimization Guidelines
- Recommended resources and web sites
- Background
- Evaluation
Seminar Outline
- Introduction
- Purpose
- Perspectives on the plastics' industry, Manufacturing
- Profits
- What is your product
- The five components of a successful plastics' application
- Concurrent engineering and its benefits
- The four processing categories
- Machine conditions vs. Plastic conditions
- Polymer Basics
- Where plastics originate
- Plastics and the environment
- Recycling of Plastics
- The making of a Polymer
- Addition polymers
- Condensation polymers
- Chain length and molecular weight distribution
- Melt Flow Rate testing
- Polymer vs. Plastics
- Moisture Sensitive Polymers
- Why dry polymers
- How to correctly dry polymers
- Moisture Analysis
- Use of regrind
- Amorphous vs. Semi-crystalline plastics
- Crystallinity
- Mold shrinkage
- Part thickness
- Cavity pressure
- Degree of Crystallinity
- Additives
- Warp
- Living hinge
- Dimensional control
- Latest heat of fusion
- Energy to melt
- Polymer Flow
- Viscosity Curve
- Injection vs. Pack & Hold (Second stage)
- Material selection and Testing; a designer's guide
- Questions that must be answered
- Properties to watch during the selection process
- What the physical tests will tell you
- Single point data vs. curves
- Doing it right the first time, changing cost $
- Polymer Testing
- Selected physical property tests
- Comparing data sheets
- Piece Part Design Overview, The Plastics Perspective; It's not nice to fool Mother Nature
- Components of Design
- The "Golden Rule" for nominal wall
- Shrinkage, Amorphous vs. Semi Crystalline
- Cooling and Warp
- Draft
- Venting
- Gating with respect to weldlines
- Overview of Injection Molding
- Machine Components
- How the machine works
- Hydraulic
- Electric
Seminar Outline
- Introduction & Overview
- Purpose
- Perspectives on the plastics' industry, manufacturing
- Profits
- What is your product
- The components of a successful plastic's application
- Concurrent engineering and its benefits
- The four molding categories
- Machine conditions vs. Plastic conditions
- Machine and Molding Overview
- When and with what did the molding industry get started
- Basic injection molding concept
- Machine components
- Machine component functions
- Videos of machine components and functions
- Optimizing First Stage: Plastic Flow Rate
- How plastics flow, viscosity
- Viscosity curve
- Viscosity vs. temperature, lot variations and injection rate
- Flow balance
- Cruise control on injection molding machines
- Two stage molding
- Case histories
- Non-return valve (check ring)
- Nozzles/mixers
- Nozzle tips
- Plastic Pressure
- Basic hydraulics
- Hydraulic Pressure vs. Melt Pressure
- Back Pressure
- Intensification Ratio
- Pressure Loss
- 1st to 2nd state switchover variations
- Gate seal vs. unseal
- Pressure vs. time graphs
- Minimizing cycle, what limits cycle time
- Clamp force
- Platen wrap
- Platen Protection for Engineering Resins
- Pressure Loss Documentation
- Cooling Rate and Time
- Cycle Percentage
- Three types of cooling
- Turbulent Flow
- Series vs. parallel circuits
- Cooling issues
- Newer methods for high temperature molds
- Infrared Imaging of mold and part
- Plastic Temperature (What's it like for the plastic to go through the machine)
- The hopper
- Drying
- The feed throat
- Barrel vs. melt temperatures
- Screw components
- Screw design for, properties, melt uniformity, color mixing & resin/color changes
- How plastics melt
- Back pressure
- Screw problems
- How to measure
- Miscellaneous
- Process Optimization Procedure
- Universal Setup Sheet Documentation
- Recommended resources and websites
- Hot Runner Startup
- Energy Saving Tips
- Items for sale
- Knowledge survey
- Evaluation