Seminar Outline

1. Introduction
   
   1. Purpose
   2. Perspectives on the plastics' industry, Injection Molding
   3. Profits
   4. The five components of a successful plastics' application
   5. Concurrent engineering and its benefits
   6. History and Trends
   7. You want it when?
2. Polymer Basics and Resin Selection
   1. Where plastics originate
   2. Chain length and molecular weight distribution
   3. Melt Flow Rate testing
   4. Moisture Sensitive Polymers
   5. Degradation
   6. Use of regrind
   7. Plastic Categories
      1. Thermoset LSR
      2. Thermoplastic
   8. Amorphous vs. Semi-crystalline plastics
      1. Crystallinity
      2. Mold shrinkage
      3. Degree of Crystallinity
      4. Additives
   9. Warp
3. Material selection and Testing; a designer's guide
   1. Questions that must be answered
   2. Properties to watch during the selection process
   3. What the physical tests will tell you
   4. Single point data vs. curves
   5. Polymer Testing
      1. Selected physical property tests
      2. Comparing data sheets
      3. Glenn Beall's check list
4. Overview of Injection Molding Processing
   1. Machine Components
   2. How the machine works
      1. Hydraulic
      2. Electric
      3. What is important for the Designer, Mold Maker: mold opening
   3. Processing
      1. Plastic flow
      2. Multi-cavity flow
      3. Press issues
      4. Identical Parts over Time/Shipments/States/Countries
      5. Process Parameters You Need to Watch, run to run; different presses; identical part
   4. Mold/Tool Design/components
      1. Tool Design
      2. Mold Components
      3. Hot vs. Cold Runner
      4. Multicavity Molds
      5. Gating
      6. Hot tips
      7. Runners Sizing
      8. Mold-filling analysis
         1. Accuracy of CAD model/Resin data, no general comments
         2. Full CAD model, all the details
         3. Accuracy of Resin data
      9. Example with benefits and issues
      10. Venting
      11. Silicone molds
5. Offshore Manufacturing (on request only)
   1. Reasons to locate offshore
   2. Reasons not to move offshore
   3. Approaches to offshore manufacturing
   4. Proactive check-ups
   5. Additional thoughts
6. Piece Part Design: The Plastics Perspective (It is not nice to fool with Mother Nature)
   1. Components of Design
      1. Nominal Wall
      2. Projections
      3. Depressions/Holes
   2. Uniform Nominal Wall
      1. Shrinkage, Amorphous vs. Semi-Crystalline
      2. Changes in nominal wall
      3. Radii
      4. Dimensional Stability - Cooling and Warp
      5. Nominal wall transition/junction/radius
      6. Filling pattern
      7. Joining flat plates
      8. Radius
      9. Warp
      10. Draft
      11. Polish/Texture
      12. Case Histories
   3. Projections
      1. Ribs
      2. Bosses
      3. Gussets
      4. Flow considerations
      5. Sink/shrink cosmetics
      6. Venting
   4. Depressions/Holes
      1. Blind Holes
      2. Through Holes
      3. Venting
      4. Fasteners
      5. How to form, tooling issues
      6. Weldlines
      7. Filling/Flow considertions
      8. Stress Management
   5. Bealls 13 Rules
   6. Tolerances
7. Hinges and Snap Joint Techniques
   1. Flexible design techniques
   2. Distortion snaps
   3. Press-fit assembly
   4. Snap-fits, snap-hook designs, cantilever snap joints, annular snap-joints, latches, permanent snap design and twist snaps.
8. Miscellaneous
   1. Instructors information
   2. Resources
   3. Checklists
   4. Essential information to be agreed upon by product designed and mold designer
   5. Test your knowledge of plastic part design