Course Overview
- Duration: 2 Days
- Certificate of attendance will be issued to those who fulfill 80% of attendance.
- An injection molded plastic part typically goes through these product life cycle stages: design, tooling, molding, assembly, and customer usage.
- This course addresses how failures can be identified and prevented.
Failures can originate from the CAD designer, the designer of the injection molding tool, and the molder.
a. A toolmaker/molder that receives CAD files and is unaware of built-in failures in the CAD files will lock in those failures if the toolmaker proceeds with cutting tool steel. DFM reviews by the toolmaker/molder typically cannot detect built-in problems like creep failures, fatigue failures, and moisture related failures.
b. An inadequate tool design can lead to warpage failures. Molded parts then don’t fit their intended assemblies.
c. A non-diligent molder overlooks critical resin preparation processes, leading to brittle parts and cosmetic failures that seem to come and go with weather changes.
These failures typically escape to the assembly stage and customer usage stage, where the maximum damage is inflicted when production is stopped. Rework, scrap, recalls, equally defective replacement parts, etc. are the repercussions that lose money for the companies.
Course Objectives
- Learn how built-in failures in the CAD files can be identified and eliminated before cutting tool steel.
- When a plastic part has nevertheless failed, be able to quickly identify the root-cause, solve the issue, and resume production.
- Warpage can be quite easily reduced with proper techniques.
- Understand the criticalness of resin preparation in the molding process.
- Lack of nonlinear FEA simulation produces inaccurate results for structural parts.
- Include creep and fatigue failures in the DFM checklist.
Who Should Attend?
- R&D Engineer
- NPI Engineer
- Tool Designers
- Molders
- Project Management
- Process Improvement Manufacturing
- Production / Supplier Quality
- Procurement
- Senior Management
Key Topics
Day 1
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Day 2
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Sink Mark
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Poor Material Knowledge (+case study)
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Drag Marks
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Fail Due to Bad FEA
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Blush
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Broken Snap-fits
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Streaks
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Rupture Press-fits
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Warpage (+ case study)
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Creep & Stress Relaxation (+ case study)
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Voids
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Fatigue (+case study)
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Moisture
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Processing Faults
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Break at Weld Lines
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Methodology
- Lecture notes
- Video Clips
- Case Studies
- Discussion
- Spot Questions
- Pre and Post questionnaire
Pre Requisite
- Basic knowledge of how plastic parts are designed
- Basic knowledge on how injection molding tools are designed
- Basic knowledge about injection molding process