Course DatesTo be verified
Cost:: €1495 (10% discount for Plastic Ireland members) including course manual, certification, lunch and refreshments
This course is a troubleshooting course. It is suitable for Operators/ Technicians/ Supervisors/ Engineers with at least a few months moulding experience or having completed the Module 1 course or similar.
It starts by covering the cycle with an in-depth review of each of the parameters making up the stages in the cycle. Theory sessions (2 hours each, one per day) include Parameters and their control, Setting up a mould with no setting sheet (7 point plan), Plastic Materials, Mould Design and Troubleshooting – with a major emphasis on troubleshooting during all sessions.
The remainder of the course is practical, setting up moulds from scratch, selecting pressures, speeds, times and strokes before building the shot up and dealing with defects as they arise. We concentrate on understanding the process with an in-depth explanation of what is happening to the material and the many ways the defect can be avoided. Using injection/ holding profiles is covered in the theory sessions and practiced on a hard-to-fill and poorly vented training mould.
A major benefit of the course is the restriction in numbers to ensure hands-on experience, and we also cover a lot of theory informally during the practical sessions.
Course Content Introduction:
Shop Practice and Safe Operating Procedures
Analysis of the Moulding Cycle
Basic Machine Set Up
Basic Machine Optimisation
Design and Construction
Processing of various thermoplastics
Correct material handling & preparation
Processing factors relating to thermoplastic materials
Process variables & how they influence part quality/product consistency
Selection of correct process parameters
Screw speed optimisation
Material and mould temperature selection
Profile injection speed
Holding pressure optimisation
Influence of one processing variable change on other variables
Practical session on machine
Optimisation of the moulding process
Setting for consistency
Practical optimisation of the moulding machine
Analysis of mould faults
Where possible we restrict Injection Moulding course numbers to just six places using up to four machines.
Our courses can be run in-company if required, or we can modify any course to your needs.
Who Should Attend?
This course builds on the content covered in our Injection Moulding Module 1 programme and so is aimed at those who have already completed Module 1, who aim to develop their troubleshooting skills. Candidates who have extensive injection moulding experience may be able to attend this course without completing Module 1 if they have otherwise gained the knowledge from the content covered in Module 1 and are able to:
- List the steps in the injection moulding cycle
- List the parameters that make up the moulding cycle and explain what these parameters do
- Explain what Back Pressure and Decompression are used for.
- Describe basic logical troubleshooting techniques for flash, short shots, sink marks and weld lines.
- Start up and shut down a moulding machine
- Remove a mould and install a new mould
- Set up mould opening/ closing speeds, strokes and pressures, set up mould safety start and stop positions and safety force and calculate clamp force requirements.
- Set up ejector speeds, pressures and find the correct ejector start and stop positions.
Safety Shoes – Required on this course
Name of Awarding Body: Quality and Qualifications Ireland QQI
Title of Programme: Injection Moulding Module 2
Award to which it leads: Injection Moulding Process Optimisation
This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications – see www.nfq.ie and is a mandatory component of major award 5M3080 – Plastics Injection Moulding.