For many customers, in-plant injection molding training is the ideal method for training employees because of the ability to use their own machines and molds and customize the training to their particular needs while working with the RJG regional team to put together an implementation plan.
Having a training plan enables companies to measure success and adapt to roadblocks. Training a large number of employees simultaneously is a cost-effective way to include teams from multiple departments and support long-term success.
Our problem-solving consultants make the RJG training experience unique. They transfer their knowledge and experience through skill-specific, industry-recognized, hands-on training from the point of view of the plastic rather than the traditional view of machine set points.
When implemented properly, your technical team will be able to successfully work together to correctly diagnose root causes as well as prevent and fix a variety of problems that can cost molders upwards of hundreds of thousands of dollars each year. RJG consultants are able to provide what online and CD-based training or “one man shows” simply cannot provide. Our proven methods are both data-driven and ROI-driven.
Below are just some of the courses we offer exclusively on an in-plant basis. Click the title for more information.
Fundamentals of Systematic Injection Molding - 3 Day
This brand-new three-day course is for technical and non-technical personnel who are associated with production of thermoplastic injection molded components. This course provides practical applications that introduce the principles of both injection molding and DECOUPLED MOLDING® processes. Areas covered include molding machine construction, process parameter selection (setting of the molding process), the effect of mold temperature control, material handling, and the use of additives with reference to component quality and consistency. Learn about the interactions between process inputs to the machine and the affects they have on the part. A DECOUPLED MOLDING® workshop is recommended as a follow up course to apply the hands-on portion of this class.
- Overview of machine and elements of process
- Basic procedures for consistent components
- Review of material types and characteristics
- Concepts of component dimensional control
Learn the proper skills for material handling.
This course walks students through the proper techniques for material handling and troubleshooting. The course explains the ins and outs of raw material management, what to consider when choosing materials, what to watch out for in product labeling, and what to consider when determining dryer requirements. Emphasis will be on the main material considerations and how drying affects the process. The objective of this course is to reduce errors and inconsistencies in processing due to material handling issues.
Understanding Material Labels
- Reading labels (trade name, common name, chemical makeup)
- Understanding tech data sheets (drying time, temperature, and dew point)
- Explaining tensile strength, specific gravity, etc.
- Types of dryers (compressed air, hot air, desiccant, pressurized)
- Basic components and diagrams
- Central vs. portable vs. press mounted
- Temp, air flow, time
- Moisture analyzers
- Cleaning (common mistakes)
- Banking temps – the good, bad & ugly
- Closed containers
- Contamination (mixing materials)
- Cumulative dry times
- Low speed high torque vs. high speed (blades, screen, etc.)
- Venture vs. vacuum vs. central (pipes, elbows, connections, cleaning, etc.)
Blending Advantages and Disadvantages
- Types (gravimetric blender, auger, screw, tumbler, or shovel)
- Regrind & Colorant
Hoses – Grounded vs. non-grounded wire
This course is offered exclusively as an in-plant course and is only available as an add-on day with the Injection Molding Essentials course.
Course length: 1 day
Class Pre-requisite: No previous training required
Successful Strategies for Tool Launch
Detect mold design issues before they become an expensive problem!
This course is intended to show how part design and mold build interact with the process. It is intended to show how to get the right mold in the right machine. A great course for part and mold designers and tooling engineers.
By challenging both designs and molds early in systematic ways, weaknesses can be quickly defined and corrected before they become costly problems. Participants will also develop the tools to measure the mold, machine, and process capability interactions to determine the best recipe for successful tool launches.
- Basic part geometry related to processing concerns
- Review part design complexities
- Sizing of the mold for the right press, more than just tie bar spacing
- How the mold design and build affects quality and total product costs
- How molds can be tried out systematically to hit the quality bulls-eye
- How plastic behaves as it travels through the stages of a process
- Systematic troubleshooting to separate material, process, design, and mold problems
- Why hot runner molds are fundamentally different
- Cooling capabilities
Successfully transfer a process from one machine to another.
Students will learn how to document an existing process and transfer it to another machine utilizing calculations, conversions, and possibly a template method through eDART® utilization to move the process. We examine robust documentation and matching processes based on plastic variables (including the use of graphical data via the eDART®, if needed), which is the most accurate method for moving molds. The class enforces the importance of thinking about the plastic variables when troubleshooting a process. There is plenty of hands-on lab time with this class, yet enough classroom time for the students to learn the core Systematic Molding concepts and ask questions.
The students will learn how to examine a setup sheet for robust processability and identify mold performance requirements. Actual machine performance will be evaluated and rules for selecting the best machine for the job will be reviewed. The process match is to match that process again and again using plastic variables as your guide and not the machine variables, which will always differ.
Machine testing will help determine if two machines are compatible by examining machine variables that may prevent transferring a mold from one machine to another:
- Barrel size
- Speed linearity
- Pressure Response
- Enough available pressure
- Even platen deflection
Four Plastic Variables:
- How to establish the proper melt
- Proper ways to document the melt
- Understanding how the plastic temperature can affect the quality of the parts
- Lab: take a melt temperature using a pyrometer
Plastic Flow Rate
- What controls the flow rate and how to establish the proper flow rate
- Proper ways to document the plastic flow rate
- Understanding how plastic flow rate can affect the quality of the parts
- Lab: complete a Rheology Curve and Cavity Imbalance to find the proper fill time for a mold
- Learning the limits of the mold through a flow rate lab study
Plastic Pressure Gradient
- How to determine if you need gate freeze or not
- Proper procedures to determine the proper pack/hold pressures
- How to document plastic pressure
- Understanding how the pack/hold pressure can affect the quality of the parts
- Lab: complete a gate seal study
- Learning the limits of the mold through pack pressure Lab Study
Plastic Cooling Rate and Time
- Proper ways to hook up the mold
- How to determine if you have turbulent flow
- How the heat of the mold influences the plastic
- How to document plastic cooling rate
- Lab: optimize the cooling and part out cycle
Course Length: 3 days