Master Molder® II

Course Description

Advanced techniques for daily processing strategies.

The Master Molder® II certificate course is designed for those who want to use cavity pressure data to monitor (detect and contain suspect parts) and to control velocity to pressure (V→P) transfer to minimize the effects of normal viscosity changes.

Using multiple development and optimization studies at the press, participants make data driven decisions to build robust processes using both DECOUPLED MOLDING II and III strategies that consider the capabilities and limitations of multiple target machines where a mold may need to be scheduled for production. Participants will document processes using Machine Independent Variables and utilize cycle graph templates to transfer processes to other capable machines more efficiently.

Participants will get extensive hands-on practice with the RJG CoPilot® System and examine historical summary and cycle graph data utilizing The Hub® to identify and correct process changes.* 

*At participating facilities only. If CoPilot or The Hub are unavailable, participants will utilize RJG’s eDART® System.

Course length: 2 weeks

Course Highlights
  • Develop and optimize processes using DECOUPLED MOLDING II and III strategies and cavity pressure data
  • Improve process repeatability with DECOUPLED MOLDING III process control techniques
  • Efficiently transfer and match process templates on different presses, focusing on what the plastic experiences in the cavity
  • Interpret graphs to troubleshoot and correct processing changes
  • Set alarms to catch short shots
Course Objectives
  1. Evaluate the processing capability of different types and sizes of molding machines to aid in appropriately matching a mold with a capable machine
  2. Identify the advantages and requirements of using a DECOUPLED MOLDING III processing strategy
  3. Develop and optimize DECOUPLED MOLDING II and III processes using data acquisition devices (CoPilot) along with machine and in-mold sensors
  4. Document robust DECOUPLED MOLDING II and III processes on a Universal Setup Sheet using Machine Independent Variables
  5. Efficiently transfer mold processes and match processes on different types and sizes of molding machines using universal setup sheet data and CoPilot cycle graph templates
  6. Compare alarms setting strategies and practice setting alarms to catch short shots
  7. Analyze cycle graph and summary graph data to identify process changes and troubleshoot process issues
  8. Identify various sensor types available for various instrumentation projects and select an appropriate cavity pressure sensor location and size
Course Prerequisites

Required:
To register for the Master Molder II class, it is required that you have received your Master Molder I certificate.

Course Recommendations

To maximize the likelihood of successfully completing the timed assessments that are required for earning a certificate, RJG strongly recommends a minimum of 3 months between the Master Molder I and Master Molder II courses to allow participants time to implement process development skills learned in Master Molder I.

For those less familiar with setup and use of the RJG CoPilot® System, advance completion of the on-demand, self-paced Meet Your Copilot course is recommended, but not required.

Availability 

This course is available publicly.

Course Schedule Overview

(Subject to change at instructor discretion)

Week 1
DayTheory, Methodology, Lab & Equipment DemosHands-on Lab Opportunities
(Small Group & Individual Practice)
1
  • Evaluate the processing capability of different molding machines using machine independent variables

  • Documenting D2 processes with MIVs

  • Examine machine performance evaluation options
  • Machine Capability Study

  • Injection Speed & Acceleration Time Study

  • Machine Orientation
2
  • Examine cycle graph curves

  • Compare types of pressure sensors and installation styles

  • CoPilot Machine Setup and Mold Setup
  • D2 vs D3 with Viscosity Shift Study
3*
  • Compare D2 and D3 processing strategies

  • Overview steps to developing D2 processes and how to convert D2 to D3

  • Theoretically vs. Practically determining required clamp force

  • Establish a good fill-only short shot for D2 processes

  • Optimizing back pressure and decompression

  • Determining gate seal with cavity pressure data
  • Develop a D2 process with instrumentation

  • Back Pressure Optimization Study

  • Decompression After Screw Back Optimization Study

  • D2 Fill-only Short Shots Study

  • Hold Time Study (Using Cavity Pressure Curve Data)

  • Clamp Force Optimization Study

  • 32-Shot Weight Capability Study
4*
  • D3 Process Documentation

  • Compare alarm setting strategies

  • Examine pressure sensor sizes and locations
  • Area of Influence Study

  • Set alarms to catch short shots on D2 processes

  • Convert a D2 to a D3 process
5*
  • Compare cycle graphs to templates

  • Overview of types and purposes of other in-mold and process monitoring sensors

  • Examining summary and cycle graph data on the Hub
  • Identify D2 and D3 process setting changes using graphs (What changed? Study)

  • Develop and Document D3 processes

  • Save D2 and D3 templates

  • Set alarms to catch shot shots on D3 processes
Week 2
DayTheory, Methodology, Lab & Equipment DemosHands-on Lab Opportunities
(Small Group & Individual Practice)
6
  • Steps to matching templates
  • Match D2 and D3 Templates
7*
  • CoPilot & Hub: Navigation and Toolsp
  • Match D3 Templates

  • Develop and Document D3 processes

  • Set alarms to catch short shots
8*
  • Content Review & Exam Preparation
  • Exam Practice Day
    (Open time in the lab for D3 process Building and Matching and Alarm Setting)
9&10*Exam1:
Part 1: Theory & Methodology
Par 2: Cycle and Summary Graph Interpretation
  • Exam 2 & 3: Develop and Document Two DECOUPLED MOLDING III Processes

  • Exam 4: Match 1 DECOUPLED MOLDING III Process

  • Exam 5: Set Alarms to Catch Short Shots
Start DateEnd DateNameLanguageLocationOpen SeatsPrice
2024/12/022024/12/13Master Molder® II2$4,445.00Register
2025/03/312025/04/11Master Molder® II5+£3,710.00Register
2025/09/222025/10/03Master Molder® II5+£3,710.00Register
2025/04/212025/05/02Master Molder® II5$4,445.00Register