This three day, total 24 hours, seminar is an advanced course, designed as a follow up to Seminar II "Injection Mold Design". This seminar is recommended for mold design engineers, mold procurement personnel, mold designers, moldmakers, mold maintenance personnel, technical management and attendants who previously participated in Seminar II. This is an advanced course. A knowledge of basic mold design and an understanding of the injection molding process are a prerequisite.

At this seminar you will....

• Participate in an unique learning experience, lectured by an instructor who has over four decades of injection molding, mold making and mold design experience.
• Enhance technical skills and experience on mold filling and material flow analysis.
• Expand awareness of alternatives available when selecting mold components, programmed core pull or opening actions, and learn to evaluate which design allows greater flexibility.
• Gain an understanding of the methods of construction.
• Receive a comprehensive custom-developed instruction manual, provided only to participants of this seminar, which will serve as a valuable source in the future.

Seminar Outline

I     Mold Engineering Principles

• Selecting the suitable molding press.
• Type of automation required.
• Polymer flow into the mold.
• Hagen-Poiseuille formula.
• Computer aided mold filling analysis.
• Pressure monitoring.
• Runner lay-out and gate position(s).

II      Mold base; alignment and thermal expansion considerations

• Leader pin and leader pin bushings.
• Parting line interlocks (lock plug, taper bar, flat taper, straight side, etc.).
• Guided ejector mechanism
• Cavity and core alignments.

III      Mold Design Concepts

• Cam action activated by: angle pin, angle block, finger cam, puller pin, etc.
• Cam action activated by ejector mechanism, internal cam, cam latch, lifters, jigglers.
• Spring loaded cams, flexi cores.
• Hydraulic activated cams, core pull cylinders and self locking cylinders.
• Heel block, slide and gib design.
• Slide retainers and slide locking devices.
• Mechanical and helical spindles, sliding devices. Post mold designs with hydraulic activated stripper plates.
• Programmed ejection, latching techniques, accelerated knockouts, and other programmed actions.
• Programmed guide rail ejections.
• Interchangeable inserts.
• Air-eject and vacuum breaks.

IV      Unscrewing, collapsible core and stack molds

• Unscrewing mold with: helical spindle, rack and pinion, hydraulic motor and other unscrewing devices.
• Collapsible core and collapsible cavity mold: installation and mold base machining.
• Stack mold: runnerless melt conveying, opening and ejection sequence.

V     Special purpose molds

• Multi-shot molding and multi-shot molds: (retracting core, over-molding transfer technology, non-rotating and rotating molds, multi-shot hot manifold and coaxial needle valve).
• Shuttle mold techniques (shuttle and rotary)
• Outsert or substrate molds, reel to reel molding.

VI      Machining methods

• EDM, wire EDM, mold texturing, ARC spray, electro-forming and nickel vapor deposition.

VII     Hot Runner Molds

• Heating plastic channel to melt temperature and controlling temperature of plastic channel. 
• Types of heating elements and isothermal conditions. Seebeck effect and Thermocouple installation. 
• Annular and cylindrical flow channels. 
• Internal heating tube and external heating manifold. Gate balance. Design concerns and gating options. 
• Sequential valve gating.

VIII     Mold Design Checklist

• A systematic approach to check major categories such as: Production requirements; Part requirements; Shrinkage and tolerances; Molding machine; Mold base or frame; Cavity; Runners; Gates; Special actions; Venting; Ejector systems; Guided ejector systems; Temperature regulation; Cylinders; Electrical; Lubrication; Maintenance; Drafting, and Documentation.

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