Injection Moulding 103
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By combining eleven of our most advanced courses on injection molding, Molding 103 provides expert level training for anyone looking to take their abilities to the next level.

This Comprehensive Training Package Includes...

Scientific Troubleshooting of Molding Defects
This series consists of four in-depth training programs that will provide participants with the knowledge base required to identify and troubleshoot over twenty-five of the most common defects encountered with injection molding processing. Users will also come away with a better understanding of how to best process, document and maintain a reliable injection molding process.

Program 1 - Introduction
This training program focuses on the 7-step process to scientific troubleshooting. Participants are also presented with information and practices on how to best process, document and maintain a reliable injection molding process.

Step 1 – Develop a Scientific Molding Process
Step 2 – Properly Document the Process Outputs
Step 3 – Examine the Defective Part and Rule Out Obvious Causes
Step 4 – Compare the Current Process with the Documented Process
Step 5 – Return the Process to the Documented Standard
Step 6 – Verify the Part and Process
Step 7 – Document all Changes Made

Program 2 - Visual Defects
Nine of the most common visual defects encountered in injection molding processing are covered within this extensive training program. Participants will be better prepared to troubleshoot these defects as each one will be defined and their respective causes and corrections will be explained in detail. Defects include:

- Flash
- Sinks and Voids
- Short Shots
- Jetting
- Gate Blush
- Burning
- Flow Lines
- Weld and Meld Lines
- Poor Surface Finish

Program 3 - Dimensional Defects
This training program will provide participants with a better understanding of how to best troubleshoot five (5) of the most common dimensional defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. These dimensional defects include:

- Large Parts
- Small Parts
- Larger Parts at the Gate
- Smaller Parts at the Gate
- Warpage

Program 4 - Material and Cycle-Related Defects
This training program provides participants with a better understanding of how to best identify and troubleshoot many of the most common Material and Cycle-Related defects encountered in injection molding. Each defect will be defined and their respective causes and corrections will be explained in detail. The material and cycle-related defects discussed in this course include:

- Splay, Bubbles, and Blisters
- Brittleness, Cracking, and Crazing
- Delamination
- Contamination
- Poor Color Distribution
- Part Sticking and Ejector Pin Marks
- Occasional Part Hang-Up


Complete Intelligent Molder Training Series
These courses were produced for technicians and process engineers that want to thoroughly evaluate both the capability and repeatability of a given injection molding machine, injection mold, or injection molding process.

Each course references three in-depth tests and will greatly benefit any participant of RJG’s classroom-based, Master Molder SM Certification Series – either as a primer or as follow-up training.

Program 1 - Machine Evaluation
- Dynamic Check Ring Repeatability Test
- Load Sensitivity Test
- Platen Deflection Test

Program 2 - Mold Evaluation
- Dynamic Cavity Imbalance Test
- Mold Deflection Test
- Tonnage Calculation Worksheet

Program 3 - Process Evaluation
- In-Mold Rheology Test
- Gate Seal Worksheet
- DECOUPLED II Process Sheet


Understanding Process Control Systems Training
This training program details process control systems and is designed to help molders make more educated choices. Process Control Systems is a must for any facility which employs (or plans to employ) closed loop process control.

- Open loop vs. closed loop process control
- How process control reduces variation
- Closed loop controllers
- Proper use of process control


The Effects of Mold Filling, Gating & Weld Lines Training
This course outlines mold filling and how different gating configurations affect filling. Also discussed are weld and meld lines and their effects on molded parts.

- Weld line occurrence and strength determination
- Gate types, location, and importance
- Fatigue and cyclic stress
- Tooling considerations


The Effects of Shrinkage, Warpage & Part Ejection Training
This course is designed to familiarize production personnel with complications that may arise during processing concerning shrinkage, warpage and ejection.

- How packing affects shrinkage and warpage
- Ejection systems for simple and complex geometry
- The effects of part geometry
- Amorphous vs. semi-crystalline polymer behavior


Processing For Profit
Processing For Profit covers techniques used for increasing profitability while maintaining part quality. The course focuses on the relationship between the material, the mold and the molding machine. Also included is practical, up-to-date information about process documentation procedures - as well as some great tips on process optimization.

- Material handling and preparation
- Process documentation and its importance
- Process optimization
- Energy conservation

15-30 hours of Professional Multimedia Training with Study Guides