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Plastic Injection Training

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Engineering, Construction and Technology

Engineering

Plastic Injection Training

For all levels

Plastic Injection Training

Master every stage of plastic injection moulding — from materials science and machine setup to defect analysis and process optimisation. This training gives you the hands-on knowledge to run efficient, high-quality production and solve real problems on the floor. Whether you are new to moulding or looking to sharpen your skills, this course delivers practical expertise that makes an immediate difference.

Dedika for businesses

What you will learn:

You will learn how plastic resins behave, how to select and dry them correctly, and how to set up an injection moulding machine from scratch. The course covers mould design fundamentals, core process parameters, and systematic defect troubleshooting using root-cause analysis tools. You will apply scientific moulding principles to develop robust process windows backed by real data. Advanced topics include hot runner maintenance, specialty processes like LSR and gas-assist moulding, automation integration, and lean manufacturing. By the end, you will have the technical knowledge to improve part quality, reduce scrap, and optimise cycle times in any production environment.

How you study in practice Plastic Injection Training

How you practise Plastic Injection Training

For companies looking to train their teams

With Dedika for Businesses, the course includes exercises and examples tailored to your own business and the specific needs of your company.

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Course content

8 Chapters • 40 LessonsDuration between 4 and 360 hours (you decide)

Chapter 1See details

Fundamentals of Plastic Materials

Lesson 1 • Introduction to Polymer Science
Covers basic polymer chemistry, molecular structure, and classification into thermoplastics and thermosets. Establishes the materials science base for all subsequent processing decisions.
Lesson 2 • Material Handling and Drying
Addresses moisture absorption, hygroscopic behaviour, and proper drying protocols before moulding. Prevents defects caused by inadequate material preparation.
Lesson 3 • Mechanical and Thermal Properties
Examines tensile strength, impact resistance, heat deflection, and shrinkage rates. Enables students to match material properties to part design requirements.
Lesson 4 • Common Injection Moulding Resins
Surveys the most widely used resins including PP, PE, ABS, PC, and nylon. Connects resin selection to part function, cost, and processability.
Lesson 5 • Additives, Colorants, and Blends
Explains how fillers, reinforcements, stabilizers, and colourants alter base resin properties. Prepares students to evaluate compounded materials for specific applications.

Chapter 2See details

Injection Moulding Machine Anatomy

Lesson 1 • The Clamping Unit
Covers toggle and hydraulic clamp mechanisms, platen design, and tie-bar systems. Explains how clamping force prevents flash and maintains mould integrity.
Lesson 2 • The Injection Unit
Details the hopper, barrel, screw, check ring, and nozzle as the plasticating and injection system. Students trace material flow from pellet to melt.
Lesson 3 • Machine Types and Tonnage
Introduces horizontal, vertical, and multi-component machine configurations and clamping force ratings. Connects machine selection to part size and production volume.
Lesson 4 • Hydraulic and Electrical Systems
Examines hydraulic pumps, valves, accumulators, and servo-electric drive systems. Connects system type to energy efficiency and repeatability.
Lesson 5 • Control Systems and HMI
Introduces the machine controller, human-machine interface, and closed-loop feedback sensors. Prepares students to navigate controls and interpret real-time process data.

Chapter 3See details

Mold Design and Construction Basics

Lesson 1 • Core, Cavity, and Parting Line
Explains core and cavity function, parting line placement, and draft angle requirements. Establishes how these features control part release and dimensional accuracy.
Lesson 2 • Ejection Systems and Venting
Details ejector pins, sleeves, stripper plates, and air-assist ejection alongside vent placement. Ensures students can assess ejection adequacy and prevent burn marks.
Lesson 3 • Cooling System Design
Addresses cooling channel layout, baffle and bubbler use, and thermal balance across the mould. Links cooling design to cycle time reduction and warpage control.
Lesson 4 • Runner and Gate Systems
Covers sprue, runner layout, gate types, and gate location best practices. Demonstrates how gating decisions affect fill balance, weld lines, and cosmetics.
Lesson 5 • Mold Types and Configurations
Surveys two-plate, three-plate, hot runner, and stack mould designs. Connects mould type selection to part geometry, cycle time, and runner waste.

Chapter 4See details

Core Process Parameters and Setup

Lesson 1 • Injection Speed and Pressure
Explains fill speed profiles, injection pressure limits, and transfer point selection. Demonstrates how speed and pressure interact to control fill pattern and shear.
Lesson 2 • Temperature Settings and Management
Covers barrel zone temperatures, mould temperature, and nozzle setpoints for common resins. Connects temperature control to melt quality, cycle time, and part appearance.
Lesson 3 • Cycle Time and Cooling Time
Breaks down total cycle time into fill, pack, cool, and open/eject phases. Teaches students to minimise cycle time without sacrificing part quality.
Lesson 4 • Packing and Holding Phase
Details pack pressure, hold time, and gate freeze-off to compensate for volumetric shrinkage. Establishes the link between packing parameters and part weight and dimensions.
Lesson 5 • Screw Recovery and Back Pressure
Addresses screw RPM, back pressure, and decompression settings during the plasticating phase. Ensures consistent melt homogeneity and prevents splay or air entrapment.

Chapter 5See details

Part Quality and Defect Analysis

Lesson 1 • Root Cause Analysis Methods
Introduces fishbone diagrams, 5-Why analysis, and process variable isolation for defect diagnosis. Equips students with structured problem-solving tools applicable to any defect.
Lesson 2 • Inspection Methods and Acceptance Criteria
Covers visual inspection standards, dimensional gauging, and cosmetic acceptance criteria. Prepares students to make pass/fail decisions aligned with customer specifications.
Lesson 3 • Process Adjustments for Defect Correction
Maps specific defects to corrective parameter changes in temperature, speed, pressure, and cooling. Teaches a systematic one-variable-at-a-time adjustment approach.
Lesson 4 • Dimensional and Structural Defects
Covers warpage, shrinkage variation, weld line weakness, and delamination as dimensional and structural failures. Connects each defect to specific process or material root causes.
Lesson 5 • Visual Defect Recognition
Catalogues sink marks, flash, short shots, burn marks, splay, and weld lines with visual examples. Builds rapid defect identification skills critical for floor-level quality control.

Chapter 6See details

Process Optimization and Scientific Molding

Lesson 1 • Process Window and Control Charts
Defines the process window through high-low parameter studies and introduces SPC control charts. Prepares students to monitor process stability and detect drift early.
Lesson 2 • Gate Seal and Pack Studies
Covers gate seal studies using part weight vs. hold time to determine minimum effective pack time. Links gate seal data to dimensional stability and sink elimination.
Lesson 3 • Viscosity and Rheology Studies
Teaches viscosity curve generation through fill-time studies and interpretation of shear-thinning behaviour. Enables selection of optimal injection speed for consistent fill.
Lesson 4 • Scientific Molding Philosophy
Introduces the decoupled moulding approach, separating fill, pack, and cooling phases for independent control. Establishes why data-driven setup outperforms trial-and-error methods.
Lesson 5 • Cooling Optimization Studies
Addresses cooling time studies, mould temperature mapping, and thermal equilibrium verification. Reduces cycle time while maintaining dimensional and cosmetic part quality.

Chapter 7See details

Mold Maintenance and Tooling Care

Lesson 1 • Hot Runner System Maintenance
Details manifold heater checks, thermocouple replacement, gate tip cleaning, and leak detection. Maintains hot runner performance and prevents costly downtime.
Lesson 2 • Mold Cleaning and Inspection
Covers cavity cleaning methods, parting line inspection, and vent clearing procedures. Prevents contamination-related defects and identifies wear before it causes scrap.
Lesson 3 • Lubrication and Moving Components
Addresses lubrication schedules for ejector pins, leader pins, slides, and lifters. Ensures smooth mould operation and prevents galling or premature component wear.
Lesson 4 • Preventive Maintenance Scheduling
Introduces shot-count-based PM intervals, maintenance logs, and mould history records. Builds a systematic approach to maximising mould life and minimising unplanned downtime.
Lesson 5 • Mold Repair and Component Replacement
Covers ejector pin replacement, insert swapping, cavity polishing, and weld repair procedures. Restores mould function and surface quality after wear or damage.

Chapter 8See details

Advanced Processing and Specialty Techniques

Lesson 1 • Micro Molding Fundamentals
Introduces micro-scale part production, precision screw design, and measurement challenges at micro tolerances. Expands student capability into medical and electronics micro-component markets.
Lesson 2 • Thin-Wall and High-Speed Molding
Addresses wall thickness limits, high injection speeds, and specialised tooling for thin-wall parts. Enables production of lightweight parts with demanding cycle time targets.
Lesson 3 • Liquid Silicone Rubber Injection Molding
Covers LSR material properties, cold runner systems, flash-free tooling, and cure cycle management. Prepares students to process silicone for medical and consumer applications.
Lesson 4 • Insert and Overmolding
Covers metal insert placement, bond strength requirements, and two-shot overmoulding sequences. Prepares students to produce multi-material assemblies with integrated components.
Lesson 5 • Gas-Assisted Injection Molding
Explains nitrogen gas injection to hollow thick sections, reduce sink marks, and lower clamp force. Covers process setup, gas pressure profiling, and part design requirements.

Certification

Your valid completion certificate

This course is for you:

Molding machine operators: ready to move beyond button-pushing into real process control.
Manufacturing technicians: seeking structured knowledge to back their hands-on floor experience.
Mechanical engineering graduates: entering the plastics industry without specialized molding training.
Quality inspectors: wanting to understand root causes behind the defects they flag.
Career changers: coming from other trades and targeting roles in plastics production.
Tooling apprentices: building foundational knowledge alongside their mold-making craft training.

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