AIM-Online offers more than your typical pre-recorded online class. Our courses are LIVE and interactive, featuring in-person instruction from our online training studio. With the use of our video camera and component viewer, our students feel like they’re directly in the training room with us.
Plastics Bootcamp is broken up into the following modules:
Students can take one or more modules as they see fit for to reach their initial education goals. Register for all five to give your brain a quality workout geared to enhancing your overall performance in the injection molding industry.
*When registering using one of the links above, please note that the modules are from one month. If you wish to sign up for modules in different months, please register using the links below.
The Plastic Materials course starts by explaining fundamental differences between amorphous and semi-crystalline materials, mechanical properties of each, drying characteristics, the importance of molecular weight and crystallinity, and shrinkage.
Students then learn various terms related to and methods used to study and describe how these materials are characterized for rheology.
Finally, the course transitions from conventional rheology into understanding plastic flow inside of an injection mold.
- Amorphous & semi-crystalline materials and properties
- Semi-crystalline materials and properties
- Temperature affect of material properties
- Video of crystallinity development
- Classifications of shrinkage
- Effect of fibers of shrinkage
- Understanding viscosity
- Shear and its effect on viscosity
- Temperature effect on viscosity
- Melt Flow Index
- Capillary rheometers
- Plastic flow in a mold
The Mold Design module begins by explaining the terminology of and differences between 2-plate and 3-plate molds.
The course then transitions into some key considerations for each of the 5 systems of the mold.
Students will then see a virtual mold tour of various types of molds and runner systems discussed in the lecture, including videos of a complete mold disassembly and reassembly.
- 2-plate vs. 3-plate molds
- Overview of ejection & venting
- Structural aspects of the mold
- Types of melt delivery systems
- Cooling design strategies
- Parting line considerations
- Shut-off angles
- Core and cavity inserts
- Virtual mold tour of 4 different molds with videos and imagery
The Mold Design+ Bootcamp module is based on the best-selling Runner & Gating Design Handbook by AIM’s founder John P. Beaumont. This module focuses on Runner and Gating Strategies for plastic injection molding. Students can take this module by itself, but is best when coupled with the Mold Design Bootcamp course.
The course begins by explaining various aspects of plastic flow within an injection mold and how it may influence shrink and warp in molded parts.
Students then learn several strategies used to decide on gate location(s) for a given part.
The course then teaches various design and layout strategies and considerations for both hot and cold runner systems including gating options and runner sizing strategies.
- Plastic flow in a mold
- Gate location & sizing strategies
- Pressure drop considerations
- Volumetric & orientation shrinkage
- Calculating shear rate
- Gate types (hot & cold)
- Types of hot runner systems
- Cold runner design strategies
- Runner sizing methods
- Cold slug wells
The Injection Molding module starts by defining processing terms while providing an overview of the various types of molding machines and their common components.
Next, the course covers common molding defects and their causes. The course then teaches the various strategies used for developing, documenting, and troubleshooting a molding process.
Students will then experience a virtual lab where a process is developed from within AIM’s molding lab.
- Processing terminology
- Common molding defects
- Strategies for resolving molding defects
- Molding machine types
- Common components of molding machines
- Hydraulic vs toggle clamps
- Injection screw designs
- Intensification ratio
- First & second stage process development strategies
- Virtual lab: process development
The Injection Molding+ Bootcamp module will teach an innovative way to effectively troubleshoot mold filling and part quality variations utilizing Flow Grouping diagnostic methodologies. This module can be taken by itself, but is best when coupled with the Injection Molding Bootcamp course.
Flow Grouping is an advanced, science-based diagnostics methodology used to identify the root cause of mold filling and part quality variations that occur during injection molding. It is fast and easy to deploy, and no additional equipment is needed.
This module will focus on the principles of plastic flow and how those apply to the Flow Grouping methodology. Ultimately students will learn how to evaluate variations short-shot data, mold maintenance data, and part quality & performance data to help identify and solve the root causes of those issues.
- Fundamental plastics rheology
- Identifying flow groups in a mold
- Analyzing flow grouping data to identify root causes
- Special considerations for hot runner molds
- Implementation by job function
The Part Design module teaches numerous design guidelines used for plastic parts.
The course will discuss the intent of each guideline along with the potential unintended negative effect that some guidelines may have on the part design.
Students will then participate in a live interactive class exercise where students will redesign a part using the guidelines presented in the course.
- Wall thickness & corner considerations
- Effect of draft on wall thickness and part filling
- Rib design guidelines and related issues
- Bosses and gussets
- Strategies for parts with living hinges
- Approaches to minimize mold complexity & cost
- Designing for assembly
- Snap fit design strategies
- Part designs with undercuts
- Class exercise: Part redesign
The Moldflow Simulation Analysis module begins with an overview of the different mesh types and mesh strategies used in the Autodesk Moldflow simulation program.
Next, the course covers how material characterization could affect the results of the simulation.
The course wraps up with an overview of the various outputs from filling, packing, cooling, and warp analyses so that students can better understand and interpret the results while considering both the capabilities and limitations of the software.
- Common uses of simulation
- Differences between midplane, dual domain, and 3D mesh types
- Meshing strategies
- Influence of the material characterization file
- Filling and packing analyses and outputs
- Process development strategies, including D.O.E’s
- Designing cooling channels with simulation
- Troubleshooting part warp
- Capabilities and limitations of the software
Who Should Attend
This is an ideal course for anyone looking to gain a well-rounded view of the injection molding industry overall, including: new hires, non-plastics engineers entering into the plastics industry, or non-technical personnel such as sales, marketing, and finance. Please note all classes are in English.
- Course PDF
- Certificate of Attendance
Take just one module: $490
Take two, three, or four modules: $425 each
*Keep scrolling for the discount code
Take five or more: $1,875(5) – $2,625(7) total ($375 each)
*Keep scrolling for the discount code
*Discount codes for multiple courses:
For two-four classes use coupon code: BootcampBundle
For five or more use: GimmeAllBootcamps