Master Molder® I
Course Description
There’s a reason why Master Molder has been the premier standard of excellence in molding for decades and continues to be a sought-after qualification.
This 8-day certificate course focuses on the best practices of DECOUPLED MOLDING® II process development, documentation, and duplication for any mold in any capable machine. To help students apply scientific molding principles, the schedule offers a blend of hands-on time with molds and machines and participative classroom time. The goal is not necessarily to be able to “run machines” but to achieve an understanding of the “whys” behind the manipulation of key processing variables from the plastic’s point of view.
During the last 2 days, participants are assessed on process development, process matching, and general molding theory and methodology through timed final exams to confirm the effective transfer of the critical knowledge and skills.
Anyone who is responsible for implementing a processing strategy in their plant or who is held accountable for quality issues are prime candidates for this training.
Students earn points through a combination of assessments: (quizzes, exams, machine performance and process study completion and documentation).
A minimum of 80 out of 100 points is required to earn a Master Molder I Certificate of Completion.
Course length: 8 Days over 2 weeks
*Notice! Beginning January 2026, most Master Molder I classes will have an 8-day duration. Some classes will extend to 10 days. Please be sure to note course dates at the time of registration.
Course Objectives
- Complete a proven sequence of data-driven studies to systematically and scientifically develop DECOUPLED MOLDING II processes that meet target production and quality standards
- Document processes using Machine Independent Variables to aid mold and process transfer
- Efficiently perform process transfers to other capable machines by converting machine independent variables to machine specific settings that require minimal adjustment to achieve target standards
- Investigate and troubleshoot processing inconsistencies and part quality issues from the plastic’s point of view through the lens of the 4 plastic variables
- Explore economic opportunities related to systematic molding methodology that can boost ROI
Course Prerequisites
It is the expectation that the participant has prior experience and is comfortable operating an injection molding machine, has successfully completed the following courses, or has equivalent knowledge/experience:
- Essentials of Injection Molding (eLearning)
- Math for Molders (eLearning)*
- Fundamentals of Systematic Injection Molding
- DECOUPLED MOLDING Workshop
- OR a minimum score on the online training placement questionnaire
*Feedback from previous course participants who were not confident in their math skills has suggested that completing the Math for Molders course before attending Master Molder I is highly beneficial. Beginning January 2026: Upon request, all Master Molder I registrants will receive complimentary access to Math for Molders. See information in your course registration confirmation email on how to request free access to this self-paced, eLearning course. Any learning purchase before January 2026 is a final sale.
Delivery Format Options
This course is available publicly or in-plant. Please contact us for requirements.
Daily Schedule Overview
(Subject to change at instructor discretion.)
Week 1 (Typically Tuesday – Friday)
| Day | Theory & Methodology | Lab Investigations |
|---|---|---|
| 1 | • Intro • Why? — Robust Processes • What? — Characteristics of Thermoplastics • How? — Molding Strategies, Focus on Decoupled Molding II • Machine Overview • Clamp Unit | • Machine Capability Study • Machine Controller Orientation • Minimum Required Clamp Force (Theoretical) • Melt Preparation Study • Shot Size Estimate |
| 2 | • Processing with the 4 Plastic Variables • Plastic Heat – Melt Preparation • Plastic Flow – First Stage, Fill | • Machine Setup • Mold & Clamp Movement • Dynamic Check Ring Repeatability Study • Load Sensitivity Study • Optimization Study • Injection Speed Linearity Study • Back Pressure Optimization Study • Decompression After Screw Back Optimization Study • Fill Flow Study • Dynamic Cavity Imbalance Study • D2 Fill-only Short Shot |
| 3 | • Plastic Flow – First Stage, Fill (Continued) • Plastic Pressure – Second Stage, Pack & Hold • Cumulative Quiz | • 2nd Stage (Hold) Pressure Study • 2nd Stage (Hold) Time Study |
| 4 | • Plastic Cooling • Documenting Processes with Machine Independent Variables (MIVs) • Cumulative Quiz | • Clamp Force Optimization Study • Cooling Time Study • 32 Shot Weight Capability Study • Process Documentation |
Week 2 (Typically Monday – Thursday)
| Day | Theory & Methodology | Lab Investigations |
|---|---|---|
| 5 | • Transferring and Matching Processes | • Build and Document D2 Processes • Transfer and Match D2 Processes |
| 6 | • Economics of Molding • Introduction to Molding with Instrumentation • Cumulative Quiz • Content Review & Exam Preparation | Practical Exam Practice: (Open time in the lab for D2 process Building and Matching) • Build and Document D2 Processes • Transfer D2 Processes |
| 7 | Exam 1: Process Development • Develop and Document a robust DECOUPLED MOLDING II Process | |
| 8 | Exam 3: Theory & Methodology | Exam 2: Process Matching • Match 1 DECOUPLED MOLDING II Process |