PLLS 0001 - Designing Plastic Parts for the Injection Molding Process
Course Description
Get a fundamental overview of plastic part design for the process of injection molding – ideal for engineers and designers who are accustomed to working with metals but are faced with metal-to-plastic concerns. Examine plastic materials, behavior and selection, engineering design, manufacturing considerations and assembly methods.
Participants in this course receive an electronic copy of “Plastic Part Design for Injection Molding,” 2/e by Robert Malloy included with registration.
Course Outline/Topics
Plastics Materials
- History of Plastics
- Plastics vs. Polymers
- Molecular Weight and Distribution
- Chemical Structure
- Morphology and Crystallinity
- Additives for Plastics
- Property Data Sheets
- Melt Flow Rate and Viscosity
The Injection Molding Process
- Molding Cycle
- Molding Machine
- The Injection Unit
- Reciprocating Screw
- Clamp System
- Ejection System
- Clamp Tonnage
Type of Injection Molds
- Two Plate Molds
- Three Plate Molds
- Hot Runner Molds
- Standard Mold Bases
Mold Cavity Filling
- Non-Isothermal Filling and Orientation
- Gating Scheme
- Types of Gates
- Runner Systems
- Mold Filling Simulations
- Flow Leaders
- Weld and Knit-lines
Cooling, Shrinkage and Warpage
- Cooling time estimations
- Cooling Circuits
- Molded Part tolerance
- Mold Shrinkage Variables
- Warpage Sinks and Voids
- Material Supplier Shrinkage Data
Part Ejection / De-molding
- Part Ejection Process
- Design for Ejection
- Establishing the Parting Line
- Ejection Forces
- Effective Surface Finish
- Ejecting Features
- Collapsible end Expandable Cores
Other Injection Molding Processes
- Insert Molding
- Multi-shot Molding
- Co-Injection Molding
- Gas Assist Molding
- Structural Foam Molding
- Liquid Silicone Molding
- Metal Injection Molding
Mechanical Property Behavior
- Short Term Stress-Strain Behavior
- Long Term Stress-Strain Behavior Molecular
Design for Enhanced Recyclability
- Primary vs. Secondary Recycling
- DFER Guidelines
- Sourcing Recycled Plastics
Prototyping Plastic Parts
- Machined Prototypes
- Rapid Prototypes
- Cast Prototypes
- Molded Prototypes
Assembly Molded Plastic Parts
- Design for Assembly
- Mechanical Fasteners
- Snap Fit Assembly
- Press Fit Assembly
- Thermal and Solvent Welding
- Adhesive Bonding
BASF Snap Fit Assembly Guide
Benefits and Learning Outcomes
- Recognize how to select an appropriate plastic material formulation
- Assess how to work within the manufacturing limitations associated with the injection molding process
- Identify how to approach plastic product development and establish end-use requirements
Prerequisites
Some knowledge of plastic materials, injection molding and engineering principles is useful but not required. Basics of these principles are introduced within the course.
Who Should Attend
Engineers and designers who are accustomed to working with metals and are faced with metal to plastic concerns.
Testimonials
Hear from past participant Natalie Gamez
"The instructor was the best one I’ve ever had for a seminar or training class. I’m definitely going to come back to UW-Milwaukee for future classes."
- Mary J. Glander, Task Force Tips
"Fantastic plastics overview class for understanding all the fundamentals of injection molding. Gives you to ability to get up to speed really quickly on plastics without coming from a background of understanding these topics."
- November 2024 Participant
"I wish I would have come to this training as soon as I started working with plastic parts instead of 3 years after, all the basics in a nutshell so we can understand how to better deal with plastics, highly recommended!"
- November 2024 Participant
Partners & Professional Credits
- Professional Development Hours 14.0 PDHs