Plastic Mould Making Course

Lesson 1 • Anatomy of an Injection Mold

Identifies every standard mold component and its function. Provides the vocabulary needed for blueprint reading and shop communication.

Lesson 2 • Toolmaker Roles and Shop Safety

Defines toolmaker responsibilities within a mold shop hierarchy. Safety protocols for machinery, chemicals, and lifting are established here.

Lesson 3 • Introduction to Plastic Molding Processes

Covers injection, compression, and blow molding fundamentals. Establishes process context for all subsequent toolmaking decisions.

Lesson 1 • Dimensional Tolerancing for Mold Components

Explains bilateral, unilateral, and limit tolerances applied to mold fits. Tolerance stack-up analysis prevents assembly interference.

Lesson 2 • Precision Measurement Instruments

Covers micrometers, calipers, dial indicators, and CMM basics. Proper instrument use ensures components meet drawing specifications.

Lesson 3 • Reading Mold Engineering Drawings

Teaches orthographic projection, section views, and GD&T symbols used in mold drawings. Correct interpretation prevents costly machining errors.

Lesson 1 • Heat Treatment Processes

Explains hardening, tempering, annealing, and stress relieving for mold steels. Proper sequencing prevents distortion and cracking in finished components.

Lesson 2 • Steel Hardness and Machinability

Relates Rockwell hardness values to machinability and wear resistance. Balancing hardness against machinability guides steel selection decisions.

Lesson 3 • Mold Steel Grades and Classifications

Surveys P-series, H-series, D-series, and stainless mold steels. Each grade's composition determines its suitability for specific resin types.

Lesson 1 • Milling Operations for Mold Plates

Covers face milling, end milling, pocket milling, and slot cutting on mold plates. Proper fixturing and climb milling technique improve surface finish.

Lesson 2 • Surface and Cylindrical Grinding

Teaches surface grinding of mold plates and cylindrical grinding of cores and pins. Grinding achieves the tight tolerances and finishes that milling cannot.

Lesson 3 • Workholding and Fixturing Strategies

Designs and selects vises, clamps, angle plates, and custom fixtures for mold work. Rigid, repeatable fixturing is essential for multi-operation mold components.

Lesson 4 • Drilling, Reaming, and Tapping

Covers precision hole-making for cooling channels, ejector pins, and fasteners. Correct drill geometry and cutting fluid use prevent breakage and oversize holes.

Lesson 1 • Wire EDM for Precision Mold Components

Applies wire EDM to cut inserts, slides, and lifters to tight tolerances. Wire EDM produces burr-free, accurate profiles in hardened tool steel.

Lesson 2 • CNC Milling Fundamentals for Mold Work

Covers G-code structure, coordinate systems, and toolpath strategies for 3-axis mold cavities. Proper toolpath selection minimises cycle time and tool wear.

Lesson 3 • CAM Software for Mold Cavity Machining

Uses CAM software to generate toolpaths from 3D mold models. Simulation and verification prevent collisions and ensure correct stock removal.

Lesson 4 • Sinker EDM for Complex Cavity Features

Explains electrode design, dielectric fluid, and spark gap control for sinker EDM. EDM machines ribs, sharp corners, and hardened steel features that cutters cannot reach.

Lesson 1 • Ejection System Design

Selects and positions ejector pins, blades, sleeves, and stripper plates for reliable part release. Ejector layout must balance force without marking part surfaces.

Lesson 2 • Parting Line and Draft Angle Design

Determines optimal parting line location and draft angles for clean part release. Poor parting line placement causes flash, undercuts, and ejection damage.

Lesson 3 • Cooling System Design and Analysis

Designs conformal and conventional cooling circuits to achieve uniform mould temperature. Efficient cooling is the single largest lever for reducing cycle time.

Lesson 4 • Gate and Runner System Design

Designs sprue, runner, and gate systems to balance fill, minimise waste, and control pressure. Gate type and location directly affect part quality and cycle time.

Lesson 1 • Mold Correction and Dimensional Adjustment

Diagnoses dimensional deviations and applies steel-safe corrections to cavity dimensions. Iterative correction cycles bring parts within drawing tolerance.

Lesson 2 • Mold Component Fitting and Benchwork

Covers hand filing, stoning, lapping, and spotting to achieve precise component fits. Benchwork quality determines mould sealing, alignment, and part surface finish.

Lesson 3 • Mold Tryout on the Injection Machine

Runs first shots to evaluate fill, balance, flash, and part dimensions. Systematic process window development separates mould issues from process issues.

Lesson 4 • Mold Assembly Sequence and Procedures

Establishes the correct build sequence to avoid interference and damage during assembly. Torque specifications and alignment checks are applied at each stage.

Lesson 1 • Mold Repair Techniques

Applies TIG welding, laser welding, and insert replacement to restore damaged mould components. Repair method selection depends on steel grade, location, and required hardness.

Lesson 2 • Common Mold Failure Modes

Identifies wear, fatigue cracking, corrosion, and galling as primary mould failure mechanisms. Understanding failure modes guides both repair strategy and future design improvements.

Lesson 3 • Mold Storage and Long-Term Preservation

Covers rust prevention, cavity protection, and proper storage conditions for idle moulds. Correct preservation prevents costly refurbishment when moulds return to production.

Lesson 4 • Troubleshooting Molded Part Defects

Links part defects such as short shots, sink marks, and warpage to mould-related root causes. Systematic diagnosis prevents misattributing mould problems to process settings.