Designing Plastic Parts

for the Injection Molding

Process

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Business, Engineering & Technology

161 West Wisconsin Ave., Ste. 6000
Milwaukee, WI 53203-2602

Learn from a Practitioner

in Plastics Technology
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Milwaukee, WI
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June 4-6, 2008
December 17-19, 2008

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Oct. 15-17, 2008

Plastic Material Selection

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Sep. 10-12, 2008

June 4-6, 2008

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Plastic Material Selection

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June 2-3, 2008

December 15-16, 2008

LOCATION:

June 2-3, 2008

December 15-16, 2008

Designing Plastic Parts

for the Injection Molding Process

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Designing Plastic Parts for the Injection Molding Process

Plastic Material Selection

June 2-3, 2008

December 15-16, 2008

June 4-6, 2008

December 17-19, 2008

CEUs: 1.2

CEUs: 1.8

Course Description:

Course Outline:

Course Description:

Course Outline:

This program is offered to engineers and designers involved in the

design of injection molded plastic parts. You will get a fundamental
overview of plastic part design for the process of injection molding.
In order to design a high quality injection molded part, the designer
must select an appropriate plastic material formulation, develop a
functional design, and must work within the manufacturing limitations
associated with the injection molding process. This course will
cover the fundamentals of plastic materials behavior and selection,
engineering design, manufacturing considerations and assembly
methods. Ideally, the participants should have some knowledge of
plastic materials, injection molding and engineering principles,
although the basics will be introduced. The course is ideal for engineers
and designers who are accustomed to working with metals and
are faced with metal to plastic concerns.

An Introduction to Plastic Materials

Keeping up with new developments in materials is a full time proposition

that few designers and engineers can afford. With large firms cutting
back on internal technical support, end users are often reliant upon
processors and material manufacturers for recommendations.
Ignorance of new technologies can mean missed opportunities for
improved performance at a reduced cost, but sorting out the fact
from the fiction in the press release is a difficult task.

Defining the Fundamentals that Determine Plastic Properties

Molecular Weight The Foundation of Polymer Technology

Textbook Included:
Plastic Part Design for Injection Molding
by Robert Malloy

Course Instructor:
Prof. Nick R. Schott
University of Massachusetts-Lowell
Lowell, Massachusetts
Prof. Nick R. Schott completed his BS in Chemical Engineering
from UC Berkeley and then went on for an MS and PhD in
Chemical Engineering at the University of Arizona. Professor
Schott has been at the Univ. of Massachusetts Lowell for the past
34 years where he has taught courses in Plastics Product Design,
Plastics Injection Mold Design, Processing and Process Control. He
is an active researcher in these areas and also a worldwide lecturer on
these subjects. Professor Schott was named a fellow of the SPE in
1986 and is also a founding member of the SPE Product Design and
Development Division. He is an editor of various books and has
authored or co-authored numerous papers in the field of Plastics
Engineering.

Historical Development
Fundamental Concepts
Molecular Weight
Repeat Unit Structure
Morphology
Effect of additives
Mechanical Property Overview
Flow Property Overview
Advantages of Plastic Materials
Limitations of Plastic Materials
Review of Injection Molding Equipment
Review of the Injection Molding Process
Review of Injection Molds
Design Considerations for Injection Molded Parts
Mold Filling Considerations
Effect of Gate Location and Type
Molecular and Fiber Orientation
Mold Filling Pressure Drop
Flow Leaders and Flow Hesitation
Mold Filling Simulations
Runner Balancing and Family Molds
Weld or Knit Lines
Shrinkage and Warpage Considerations
Part Ejection Considerations
Mechanical Behavior pf Plastic Materials
Approaching Plastic Product Development
Establishing End Use Requirements
Conceptual Design
Initial Candidate Material Selection Procedures
Design Based Upon the Materials Selected
Final Materials Selection
Manufacturing Related Design Modifications
Prototyping and Testing
Production Tooling and Manufacturing
Plastic Part Prototyping Techniques
Assembly Techniques for Injection Molded Parts
Summary and Conclusion

This short course in material selection organizes the crowded landscape

by breaking the material selection process down to its fundamental
elements. It then uses this foundation to build a systematic approach
to determining cost effective solutions that combine the material
selection with the processing and design considerations.
Participants will learn to distinguish streams of data from truly
valuable information and will be able to ask the right questions
of their suppliers in order to arrive at viable material selections.
The emphasis of the course is on thermoplastics in the injection
molding process.

Textbook Included:
Polymer Science and Technology
by Joel R. Fried

Course Instructor:
Mike Sepe
The Material Analyst
Dickten and Masch Manufacturing Company

Program Schedule Both Courses:

UWM reserves the right to amend the program should circumstances warrant such action.
In the event of course cancellation, the University of WisconsinMilwaukee will
reschedule the course, refund course fees or apply the fee payment to any other SCE
course offered in the next twelve months. Liability for course cancellation is specifically
limited to the amount of the pre-paid course fees and excludes any incidental or
consequential damages.

First Day Only:

7:30-8am
8:10am

Registration/Check In
Welcome

Seminar Format Each Day:

8am-12 Noon
Lecture and Discussion
12 Noon
Lunch
1-4:30pm
Lecture and Discussion

Michael Sepe brings over 30 years of experience in the plastics

industry, focused on injection molding and material testing. His
work includes hands-on plant experience coupled with business
management at several organizational levels. His primary interests
involve the integration of process technology and material testing
and analysis to competitively produce high quality products. He
teaches public courses on these subjects at several universities and
writes a monthly article for Injection Molding Magazine on material
analysis and its application to the solution of product performance
and processing problems. He has written contributing chapters for
a number of industry publications on material properties and injection
molding and has presented over 25 ANTEC papers on a variety of
topics related to the use of analysis to improve product quality.
Michael Sepe has authored a book on the use of dynamic mechanical
analysis as an engineering tool.

Last day adjournment at 3:30pm.

www.sce-eng.uwm.edu

The Relationship to Viscosity

The Relationship to Properties
New Technologies that Change the Rules
Methods of Polymerization Addition and Condensation Polymers
Polarity Why Nylons Absorb Water and Polyethylenes
Absorb Gasoline
Amorphous and Semi-Crystalline Polymers
The One Thing You Must Know About Polymer Structure
Detecting the Presence of Crystalline Structure
Effects on Processing
Effects on Properties
The Role of Polymer Blends
Property Evaluations Short Term
Tensile, Flexural, and Compressive Properties
Impact Properties Various Methods of Measurement
Thermal Properties
Other Properties Flammability, Wear Resistance, Optical, etc.
The Role of Material Property Databases and Selection Utilities
Property Evaluations Long Term
Effects of Temperature
Chemical Resistance Effects of Temperature and Time
Creep Resistance, Stress Relaxation, and Fatigue

Accelerated Testing Methods Advantages and Pitfalls

The Fundamental Equivalence of Temperature and Time
Environment Stress Crack Resistance
Radiation Resistance Weathering, Ultraviolet, Sterilization
Property Modifications
Fillers and Reinforcements
Impact Modifiers
Colorants
Stabilizers
Establishing the Cost / Performance Profile
Defining Application Requirements
Matching Requirements of A Cost Effective Material Family
Design Properties Versus Inherent Properties
Designing for manufacturing Wall Thickness,Viscosity,

& Process Selection

The Role of Simulation
Selecting A Material Supplier
Case Studies Successes and Failures