Design and Manufacturing of Plastic Injection Molds

Theoretical with software and Practical in workshop

• Introduction to plastic injection process.

• Basics and rules of plastic product design.

• Introduction to the chemical bases of polymers and plastic materials selection.

• Main mold types, components and their applications.

• Metallic material selection for mold components.

• Heat treatment and surface treatment of injection molds

• Standards mold sets.

• Main design consideration of injection molds

• Design of sprue, runner and gate systems.

• Design of cooling and venting systems.

• Design of different ejection systems.

• Limitations and recommendations of different mold systems.

• Mold filling process design  and control.

• Design of injection cycles.

• Die making process, limitations and recommendations

• Use of Unigraphics NX & DelCam Mold-Maker software packages for mold design.

• Using of Moldflow to optimize the plastic mold design.

•  Mold maintenance and production trouble shootings and problem solving.

• Case studies and practical applications

Computer tools for Industrial development 

CAD/CAE/CAM/RPM

• Characteristics of global market and future products.

• Problems with current production tools.

• Introduction to CAD/CAE/CAM software.

• Using CAD software to improve product design and market new ideas.

• Using CAE software to design cost effective, longer-life and human-safe products.

• Using CAM software to manufacture high accuracy products economically.

• Fully computerized manufacturing systems.

• Using 3D scanning and CMM to facilitate reverse engineering and quality control.

• Basics of 3D printing and Rapid Prototyping.

• RP technologies, machines and applications.

• Examples, Case Studies – Project.

Duration:  30 hours 

Innovative product design tools:

 Reverse Engineering and   Rapid Prototyping

• Keys and requirements for innovative products.

• Using Internet to identify new product properties and global market needs.

• Introduction to reverse engineering.

• Engineering measurements tools and skills.

• Capturing geometry and free form surfaces.

• Basic of 3D point and surface scanning.

• 3D Scanners types.

• Transferring free surfaces to cloud of points.

• Transferring cloud of points to CAD models.

• Editing and correcting scanned models.

• Basics of 3D printing and Rapid Prototyping.

• RP technologies and machines.

• Applications of RP.

• Using RP to build medical implants.

• Examples, Case Studies – Project.

Duration:  30 hours

Basics of Electronic Drafting…

AutoCAD^© 2D  

• Basics of electronic drafting and modeling.

• Introduction to AutoCAD product line.

• Commands, coordinates and viewing skills.

• Creating basic 2D shapes using drawing tools,

• Editing and selection tools to speed up the work.

• Grips, object snap, groups, layers and linetypes

• Hatching, styled text and associative dimensions.

• Advanced drawing and editing tools.

• Blocks, external reference files and image files.

• Standard drawing setup, printing and plotting.

• Examples, Case Studies – Project.

Duration:  60 hours

Basics of 3D modeling…

AutoCAD^© 3D

• Concepts and methods of 3D modeling.

• AutCAD 3D workspace and 3D coordinates.

• User specified coordinate systems and plans.

• Creating 3D solids from 2D sketches.

• 3D features and Boolean modeling tools.

• 3D viewing techniques and view ports.

• Editing, modifying and checking solids.

• 3D curves and surface modeling tools.

• Using 3D scanner to capture complex surfaces.

• Assigning materials and physical properties.

• Rendering, image mapping and animation.

• Exporting models to CAM/CAE programs.

• Basics of 3D printing and Rapid Prototyping.

• Printing 3D models using RP machines.

• Examples, Case Studies – Project.

Duration:  60 hours

Integrated CAD/CAE/CAM tools...

Unigraphics NX^© 6  (I)

• Modeling and CAD/CAM/CAE theories.

• Basics of gateway interface and applications.

• Constructions of CS and working axes and plans.

• Making 2D constrained sketches using Sketcher.

• Creating primitive, swept and Boolean solids.

• Using expressions for parametric modeling.

• Viewing, selecting and transforming objects.

• Placing design features such as holes, slots, etc.

• Using part browser to identify and modify features.

• Visualizing solids: rendering and animation.

• Automatic creation of 2D orthographic views.

• Automatic creation of section and detail views.

• Creating and editing text and annotations.

• Basics of 3D printing and Rapid Prototyping.

• Printing 3D models using RP machines.

• Examples, Case Studies – Project.

Duration:  60 hours

Integrated CAD/CAE/CAM tools...

Unigraphics NX^© 6  (II)

• Basic assembly modeling and mating conditions.

• Surface operations and free form modeling.

• Extracting objects and exchange solid files.

• Using Mold Wizard Product Design Advisor to design dies and molds.

• Defining parting geometry and the associative core and cavity geometry.

• Appling shrink factors and tooling inserts and using Standard Part Libraries to select common parts.

• Extracting a Bill of Materials.

• Introduction of Finite Element Analysis tools.

• Examples for the simulation of part behavior under mechanical and thermal stresses.

• Assembly modeling for manufacturing.

• Manufacturing and machining environment

• Milling, drilling, turning and multi-axes operations

• Examples, Case Studies – Project.

Duration:  30 hours

Advanced Mechanical Analysis Tools...

 Ansys^© 11   

• Basics of Finite Element Analysis.

• Simple numerical examples.

• Concept of Pre, Post processors and solvers.

• ANSYS pre-processing environment.

• Creating nodes and elements by coordinates.

• Importing models from CAD software.

• Automatic generation of 2D and 3D meshes.

• Defining material and element properties

• Manipulating the display of elements

• Mesh refining to improve accuracy.

• Loads and boundary condition sets.

• Checking the finite element model

• Performing the analysis

• Post-processing the model

• Displaying results in different formats.

• Analysis of non-linear materials.

• Analysis of time varying loads.

• Structural durability (Fatigue) analysis.

• Case Studies – Project.

Duration:  60 hours

Die and Mold Design and Manufacturing...

Basic Mold Engineering

• Introduction to plastic mold engineering.

• Basic plastic mold functions.

• Mold design requirements and guidelines.

• Injections machines systems.

• Plastic types, identifications and shrinkage.

• Selection of parting line and cavity locations.

• Mold layout, surface, gates and runners.

• Mold cooling, venting, ejection and stacks.

• Mold material specifications.

• Heat treatment to improve mold life.

• Mold design standard specifications.

• Air and oil actuators.

• Rules and calculations for designers.

• Monitoring mold performance.

• Analysis of mold and product defects.

• Mold maintenance and repair.

• Examples, Case Studies – Project.

Duration:  60 hours

Die and Mold Design and Manufacturing...

 Moldflow Plastic Advisor ^© 8

• Revision on plastic mold functions and mold design requirements and guidelines.

• Injections machines systems.

• Plastic types, identifications and shrinkage.

• Introduction to fluid flow and heat transfer.

• Moldflow Plastic Advisor screen manipulation.

• Importing 3D CAD models to MPA.

• Selection of part and mold materials.

• Selection of working conditions.

• Construction of cooling and heating lines.

• Simulations of the distribution of temperature, pressure, flow and shrinkage.

• Checking for geometry defects and errors.

• Prediction of air traps, weld lines and fill time.

• Advanced analysis features of MPA.

• Optimization of part and mold design.

• Examples, Case Studies – Project.

Duration:  70 hours

Die and Mold Design and Manufacturing...

Mold Manufacturing

• Basics of engineering materials.

• Shaping and forming processes.

• Machining processes: introduction, requirements and guidelines.

• Machine tools and applications.

• Mold manufacturing standard specifications.

• Optimization of mold manufacturing.

• Monitoring mold performance.

• Analysis of mold and product defects.

• Mold maintenance and repair.

• Workshop hours.

• Examples, Case Studies – Project.

Duration:  60 hours