International Training Program

Plastic Injection
Molding Technology
26-28 September 2011, Impiana KLCC Hotel Kuala Lumpur, Malaysia
This 3-day program on injection molding covers injection molding fundamentals, mold design, mold maintenance and troubleshooting process problems. This program is aimed for engineers, technical service and factory managers related to injection molding.

Program Content
SESSION 1 (Injection Molding Fundamentals) - Advantages and Disadvantages of Injection Molding;
Applications of Injection Molding (What is possible with injection molded products); The Injection Molding Cycle (Clamping, Injection, Ejection); Components & functions of an Injection Molding Machines (Injection Unit - Screw, Barrel, Nozzle, Screw Drive System; Clamping Unit Mechanical, Hydraulic, Tie Bar Less Clamping System; Drives Hydraulic, Electric, Hybrids; Plastic Materials - How they influence machine choice); Injection Molding Machine Types (Standard Injection Molding Machines, Fast Cycling Machines, Plunger / Shooting Pot Machines, Multi-Component Machines, Micro Injection Molding Machines, Gas Assisted Molding Machines, Water Assisted Molding machines, MultiStation Injection Molding Machines, Low-Pressure Injection Molding Machines, In-Mold Decoration / In-Mold Labelling Machines) ; Injection Control (Profiled / velocity-controlled filling, The feedback loop, Charting and interpretation of pressure / velocity curves, Pressure limited velocity); Plastics Flow during Injection Molding (How plastic Flows, Laminar flow and fountain flow, Orientation effects, Effects of temperature, pressure, and molecular weight); Shrinkage and Volume Changes (Pressure-volume-temperature relationship, Amorphous and semi-crystalline materials, Cavity pressure and mold shrinkage, Flow and temperature effects, Fiber fillers and their effects); Molding Strategies (Traditional molding, Two-stage molding, Velocity to pressure transfer methods , Process monitoring, Initial mold tryout procedure)

SESSION 2 (Injection Mold Design) - Function of Injection Molds; Mold Types (Single cavity, Multi cavity, 2
plate molds, 3 plate molds, Hot runner molds); Mold Layout (Mold component parts (Bases), Selection of mold bases, Effects of part design on mold design, Use of inserts and sub-inserts in construction, Balancing of forces in a molds component parts); Tolerances achievable in Mold and Part Design (Tolerances of mold components and molded articles, Sensitivity of tolerances to molding material and process); Mold Steels (Mold material selection criteria, Treatments to modify steel properties, Components requiring treatment); Mold Strength (Miscellaneous calculations, Metal fatigue issues, Wear and undesired hobbing); Ejection (Types of ejection, Actuation and interface to the molding machine, Cosmetic tradeoffs); Cooling (Basic cooling principles & its importance to product quality, Serial and parallel cooling layouts, Machining cooling lines, Cooling across multiple mold components: (inserts, core pins, etc.) ,Cooling differences with Amorphous & Crystalline plastics); Gating (Types of gating, Designing the proper gate for the molding material, Balanced runner layout); Hot Runners (Types of standard systems, Selection and advantages of using a hot runner system, Needle valve gate types: pneumatic, hydraulic & electric, Needle valve gates & cascade gating); Venting (Importance of venting in injection molding, Designing for proper venting); New Molds (Specifying the build, Product take-out: cavity layout implications, Designing for easy maintenance, Measurements and start-up checks, Setting up a maintenance system, Inspecting the new mold); Older Molds (What to document before, and when the mold arrives, Establishing cleaning / maintenance schedule, Spare parts inventory); CAE in Mold Design (Flow analysis for proper gate selection, Cooling analysis for optimal cycle times, Emerging technologies for mold design)

SESSION 3 (Mold Maintenance and Mold Setting): Mold Maintenance (Problems associated with poor
maintenance, Storage, Corrosion, Cooling Media Conditioning & Filtration, Documentation & logging repair work, Spares itinerary); Mold Setting Considerations (Die height requirements, Platen usage , Shot capacity, Ejector stroke, Daylight requirements, Projected area and clamp force requirements) ; Set-up of an Injection Mold (Tool change preparation (Check list), Systematic set-up procedure, Setting Toggle clamp, Setting Hydraulic Clamping system, Attachment methods; mold to machine, Ejection systems: Types, Tied / coupled ejector/ Ejection Monitoring, Mold protection systems, Services (Coolant /Power / Signals /Air), Optimising mold movements & actions for safety with speed, Handling systems, Takeout devices)

SESSION 4 (Optimization of Injection Molding Process) - Establish customer acceptance levels; Mold trial
procedures; Process parameters to measure process stability ; Process Parameter profiles: Why & when to use them (Injection, Holding, Plasticizing, Back pressure) ; Tolerances for a stable process; Controlling check ring closure & opening; Basic introduction to Design of Experiments / Taguchi optimization methods

SESSION 5 (Troubleshooting of Injection Molding) - Troubleshooting Procedures and Logic (How to

effectively approach, analyze, and implement troubleshooting procedures); Exploring Root Causes (Explore the root causes of the various defects from the perspective of the plastic material as it fills, compresses, and cools within the cavity); Surface Defects (Flow lines and jetting, Splay (moisture or trapped air), Haze, blush, and poor gloss, Orange peel and surface ripples, Gate blush and gate splay, Stringing witness, Gate vestige); Burning and Contamination Problems (Burn marks and black specks, Burn streaks, Contamination, Discoloration or poor color match, Burning at the Gate); Physical Problems (Flash and short shots, Sink marks, Vacuum voids and bubbles, Blisters and delamination) ; Geometry Maintenance Problems (Under- or over-sized dimensions, Poor dimensional repeatability, Warpage and bowing, post molding shrinkage) ; Structural Defects (Cracking, crazing, and brittleness, Weld lines, Stuck parts and pin push marks, Long gates and plugged gates, Drag marks and molded part damage)

SESSION 6 (Innovative & Tech Trends in Injection Molding) - Multi Layer Sandwich Molding; Over
Molding; Gas Injection Technology; Water Injection Technology; Injection Compression Molding; Long Fibre Molding; Micro Molding; Introduction to Rapid Manufacturing Technologies (Fused Deposition Modeling, Selective Laser Sintering, Light curing resins, Uses in mold construction) Program Language: ENGLISH Program Agenda: 09.00 am to 05.00 pm (Each Day)

Program Instructor: David Jevons, Polybridge Training Limited, UK

David Jeavons, proprietor of Polybridge Training Ltd, UK has spent his whole working life in the Injection Molding Industry. Upon leaving Engineering college in 1969 he served a 4yr indentured apprenticeship with GKN Sankey Ltd. Leaving thereafter to pursue a career in materials technology and then research with RAPRA. After a period with 2 well known trade molders he worked on behalf of The Ford Motor Company. The late 1980's saw him as part of the PPITB as a technical instructor, moving to become Technical Manager with NETSTAL UK Ltd, eventually leading to the foundation of Polybridge in 1991. Since the mid 1990's he has been closely involved with ENGEL UK Ltd, providing training and technical support on their behalf. Formed in 1991 Polybridge Training Ltd has built a reputation for customer specific, bespoke training worldwide. Polybridge Training's clients include some of the largest companies in the industry a few of which are listed as follows: Rapra, Engel, Netstal, Visteon, Sony, Hoover, Mikron, IMI, Metalite, Glazpart, Rexam, FKI, Morgan Materials Technology, Braun, Gillette, Oral-B, Sims-Portex, Britax, Sumaria Industries (Kenya), AWRE, M.O.D., PERA, Rhone Poulenc, ICI, EMS-Grilon, Ford, Precision Valve

FREE BOOK for All Delegates

Injection Molding Process - Troubleshooting & Improvement published by Plastic Industry Academy. This book has papers written by injection molding experts on how to improve injection molding process and troubleshooting problems experienced by injection molders.

Program Organizer: Plastic Industry Academy @ TechnoBiz

Plastic Industry Academy @ TechnoBiz is a division at TechnoBiz Communications Co., Ltd., based in Bangkok, Thailand. This academy is a knowledge-based and educational platform for plastic industries. It offers technical training programs and conferences for engineers and technical personnel in plastic industries. It publishes bimonthly magazine Plastic Technology Asia, which covers latest developments in plastics technology. Reference Guides on Plastics Industry Process Improvement are being published by this academy. Please visit www.plasticindustry-academy.com for more information.

Tel: 66-2-933 0077 Fax: 66-2-538 1325 Email: training@plasticindustry-academy.com

Registration Form Injection Molding Technology

26-28 September 2011, Impiana KLCC Hotel, Kuala Lumpur, Malaysia
Company Name: . Address .. Tel... Fax .. Email. Contact Person . Mobile Email..

Participant Names
Participant 1 Position Email Participant 2 Position Email Participant 3 Position Email Participant 4 Position Email Participant 5 Position Email Participant 6 Position Email

Registration Fee/Person (US$)

Before 15 August 2011 950 US$ Before 10 Sept 2011 1,100 US$ After 10 Sept 2011 1,300 US$

Remark: Payment is required with registration. The registration fee includes training documentation, lunch and refreshments during the program. Group Promotion before 15 Aug11: Register for 2 delegates from the same company, 3rd delegate participation is FREE. Group Promotion after 15 August 2011: Register for 3 delegates from the same company, 4th delegate participation is FREE.

Payment Methods
Bank Transfer to Bangkok Bank, Ratchada-Latphrao Road Branch, A/C No: 177-0-70727-9 A/C Name: TechnoBiz Communications Co., Ltd., Swift Code: BKKBTHBK (Kindly make payment for all bank charges and fax /email bank slip ) Visa Master Card (5% bank fee for credit card processing will be applied)

Credit Card

Card Number Cardholder Name .. Last 3 digits on signature panel Card Expiry Date .. Signature of Cardholder Date ..

Please send completed registration form to Plastic Industry Academy@ TechnoBiz, TechnoBiz Communications Co., Ltd. 2521/27, Lardprao Road, Khlongchaokhunsingha, Wangthonglang, Bangkok 10310 Thailand Tel: 66-2-933 0077 Fax: 66-2-538 1325 Cell: 66-81-988 6874 Email: training@plasticindustry-academy.com Web: www.plasticindustry-academy.com Contact Person: Khun Sirinthip, Program Coordinator W