Course 1: Basic

Programme Overview

 

The Injection Moulding Driver Licence® is a systematic and all-round training programme designed for the plastics injection moulding industry. There are 5 courses covering topics from material science, moulding machine, moulding process, periphery equipment and mould. From basic to expert levels, the courses progressively improve the participants’ injection moulding knowledge and raise their ability to diagnose and solve problems effectively.

Programme Benefits

 

Its main differentiating advantage compared to other training programs is that the awarded certificate is like a driver’s licence: it is given only after a student has passed the final examination, and not on the basis of attendance. Passing the examination proves that the student has understood the training and is able to transport the knowledge into the practice of injection moulding.

Students who pass the stringent Injection Moulding Driver Licence® examination will possess injection moulding expertise equivalent to their German counterparts and become an application engineer in the plastics industry.

Target Industry

 

Injection Moulding Industry

Prerequisite

 

No

Course Content

General

Introduction to the Injection Moulding Shop

Material Science

Learn the different characteristics and properties of crystalline and amorphous materials. Seven different standard plastic materials are chosen to demonstrate how the end-product features differ due to the processing conditions and their material properties. Further market applications are also discussed.

Moulding Machine

Understand the operation of the injection moulding machine under realistic moulding cycles. Learn about the major core units of the injection moulding machine, including the control unit, clamping unit, injection unit, and its auxiliary components. Discuss two major control unit principles: Open loop and closed loop systems. Explain the working principles of various types of clamping units and how to estimate clamping force. Explore the mechanisms of injection unit screw design and principles. Learn how to choose suitable screw strokes for materials. Discuss important auxiliary components such as check valves and nozzles.

Moulding Process

Explain how to effectively adjust the injection speed and pressure, and also learn to determine injection moulding process parameters. Explain the basics of filling row analysis.

Periphery Equipment

Briefly discuss mould temperature control, dehumidifying drying, colour mixing, and maintenance. Explain how optimised mould temperature control is crucial to reduce cycle time and improve quality. We further discuss how to design and produce the cooling channels and its related maintenance to reach good mould temperature control and stabilised quality. We also discuss the effect of dehumidifying and its practice. The last part is to understand the colour mixing methods and effective ways to change materials and colours as part of the Single Minute Exchange of Die (SMED).

Mould

Discuss the basic components of a standard injection mould: injection, cooling, mechanical and ejection system. We introduce modern injection mould techniques based on types of platen assembly and mould base rotation. A two-platen system is used to explain the design of the mould and its mechanisms. We also discuss the characteristics of injection system based on:

  1. Gate selection and cold runner design, three-platen mould design
  2. Hot runner principles and practice

Special Technology

Insert and outsert moulding technology.

Moulding Defects

Discuss at least 8 different types of moulding defects. Students will learn to identify problems as well as remedial measures to correct these moulding defects.

Practical Trial

Create a filling rolls for analysis. This trial is completed at the participant’s factory using an existing mould and machine. The student will bring the homework to Course 2 for discussion.

Examination

20 Theory questions.

Available language

German, English, Chinese, Russian and Bahasa Melayu

Methodology

Problem solving

Project work

Production-based learning

Certification Body

Injection Moulding Driver Licence® awarded by German Training Centre for Injection Moulding

Duration

2 days