DECOUPLED MOLDING SM

These courses convey many of the concepts and theories covered within the RJG DECOUPLED MOLDING SM training seminars.

This four disc series starts with the major components of the molding process, and progresses to systematic troubleshooting.

The DECOUPLED MOLDING SM system is an ideal processing method intended for anyone interested in optimizing an injection molding process.

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Intelligent Molder

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.

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Math for Molders

This two-part training program was created for all personnel within the injection molding industry who would like to expand or fine tune their math skills.

These courses will greatly benefit any participant of RJG’s classroom-based, Master Molder SM Certification Series either as a primer or as follow-up training.

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Process Control Systems

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

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Understanding Processing Parameters

This two part course details injection molding processing parameters. Processing Parameters discusses individual parameters to help molders maintain more control of their processes. Participants will learn about processing parameters as they relate to the various phases of the injection molding process.

• Description of molding parameters
• Procedures for optimizing several different molding parameters
• The importance of machine calibration
• In-depth considerations for injection, packing, cooling and part removal

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RJG’s eDART™

This course was created for production personnel that monitor and optimize injection molding processes equipped with RJG’s eDART™ process controllers. This course will greatly benefit setup personnel, process engineers, machine operators, and managers that use, or plan on using, an eDART™ system.

Participants will be better prepared to establish the following:

• Improved processing methods
• Increased operation efficiency
• Machine and process analysis
• Automated quality control
• Improved process stability

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An Introduction to Injection Molding

This course provides participants with a general introduction to the plastics industry. The primary focus of this training program is the day-to-day operations of a typical injection molding facility.

An Introduction to Injection Molding was created for newcomers to the injection molding industry or anyone that would like to learn more about plastics. We recommend that new hires take this course before participating in our Injection Molding Basics series.

• An overview of plastics and the industry
• A typical molding facility
• General plant safety
• An introduction to the molding process
• Molding machine components
• Material handling
• Injection mold terminology
• Common part defects

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Injection Molding Basics

Our Basics series provides participants with a general understanding of the three major aspects of injection molding; the injection molding machine, the molding process, and the injection mold. These programs use 3D animation to demonstrate the inner workings of the machine and mold and to easily convey otherwise complex concepts. Important safety precautions are stressed throughout these training programs.

These basic injection molding training programs are ideal for new hires, yet also serve as an excellent refresher course for any employee involved in plastics processing; from operators and technicians to management and setup personnel.

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Injection Molding Hydraulics

This course demonstrates the importance of hydraulics in the injection molding process. Machine operators will learn ways to reduce wear on hydraulic components, while more advanced employees concentrate on hydraulic print reading and theory.

• Basic hydraulic theory
• The role of hydraulics in injection molding
• The function and purpose of hydraulic components
• Recognition of hydraulic symbols
• Directional valves and flow controls
• Hydraulic pumps and motors
• Proportional valves and servo valves
• Hydraulic fluid management

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Injection Mold Maintenance

This program details procedures for proper mold care before, during, and after a production run - stressing important safety considerations for mold handling. From mold storage to part removal, this course provides participants with good mold maintenance habits and aims to extend tool life & increase its productivity.

• Proper mold maintenance
• Mold storage and preparation
• Water line maintenance
• Techniques for extending tool life

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Injection Molding Machine Maintenance

Designed to introduce the many maintenance considerations for an injection molding machine. Participants are also shown newer technologies; such as laser leveling, ultrasonic tie bar stretch measuring, and portable machine process monitors.

• Basic machine maintenance & safety concerns
• Fluid and platen maintenance
• Screw and barrel maintenance
• Preventative maintenance & logging

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Understanding 3-Phase Power

Understanding 3Ø Power covers power generation, transformation and distribution, and is designed for training all maintenance personnel that use 3Ø power applications. Proper understanding of 3Ø power will help employees balance power loads, improve power factors, and make more efficient decisions about usage and management.

• Power generation and distribution inside the plant
• WYE and Delta power systems
• The need for balanced circuits
• An introduction to Motor Control Centers (MCC)
• AC to DC power conversions
• Power Factor calculations and corrections

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Electric Injection Molding

Our two Electric Injection Molding courses will provide participants with a better understanding of the benefits and capabilities of modern all-electric injection molding machines. Safety concerns particular to electric molding machines are also covered.

These programs identify critical differences between hydraulic and all-electric injection molding machines – and teach participants how to optimize a given process running on an electric molding machine so that they can take advantage of those differences.

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The Effects of Mold Filling, Gating & Weld Lines

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

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Establishing an Injection Molding Process

This program shows participants how to quickly and effectively establish an injection molding process. Important safety issues associated with process set-up are stressed throughout the course. This program will also help molders reduce set-up and cycle times.

• Material preparation, drying and mixing
• Screw and barrel cleaning
• Guidelines for setting each processing parameter
• Procedures for proper injection velocity profile set-up
• Proper clamp and part removal settings

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The Effects of Shrinkage, Warpage & Part Ejection

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

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Injection Mold Setup

This two part program covers the die-setting process from start to finish with an emphasis on safety. Proper procedures for mold inspection, preparation and installation are outlined. Injection Mold Setup also covers setup procedures for hydraulic, toggle and hydro-mechanical clamp systems.

• Proper mold installation procedures
• Important safety considerations
• Proper water line set-up
• Safety precautions for mold setup

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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

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Troubleshooting Defects

The goal of this two part program is to reduce scrap and improve part quality. Troubleshooting Defects is packed with information about problems encountered during the injection molding process. This course will help all members of your production team identify, isolate and eliminate the root cause of molded part problems.

• Terminology and descriptions of molding defects
• Systematic corrective troubleshooting procedures
• Process documentation to ease the troubleshooting process
• Long-term and short-term effects of process changes

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Understanding Plastics

This program explains how and why plastics are different and cites several different types of polymers and processing considerations. Understanding Plastics emphasizes material handling, explains regrind, and covers the effects that moisture can have on molded part properties during processing.

• The definition of plastics
• Polymer classification
• Material properties affected by processing
• Proper material handling techniques
• Processing characteristics of virgin and regrind

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