Template Matching

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:

Plastic Temperature

  • 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