Injection Moulding Module 2 - Process Optimisation

Course Location(s): 
Course Venue(s): 

First Polymer Training Skillnet

Enrollment and Start Date(s): 

Dates: 23rd - 26th March 2015
19th - 22nd October 2015

4 days
Qualification Type: 
Level 5 Component Award (Level 5 NFQ)
Attendance Options: 
Part time
Course Fee (Price in Euro): 

€1,495. Inclusive of course manual, lunch and refreshments and QQI Level 5 Exam.

Available to Unemployed: 
Course Content: 

This course is a troubleshooting course. It is suitable for Operators / Technicians / Supervisors / Engineers with at least a few months moulding experience, or having completed the Module 1 course or similar.

It starts by covering the cycle with an in-depth review of each of the parameters making up the stages in the cycle. Theory sessions (2 hours each, one per day) include Parameters and their control, Setting up a mould with no setting sheet (7 point plan), Plastic Materials, Mould Design and Troubleshooting - with a major emphasis on troubleshooting during all sessions.

The remainder of the course is practical, setting up moulds from scratch, selecting pressures, speeds, times and strokes before building the shot up and dealing with defects as they arise. We concentrate on understanding the process with an in-depth explanation of what is happening to the material and the many ways the defect can be avoided. Using injection/ holding profiles is covered in the theory sessions and practiced on a hard-to-fill and poorly vented training mould.

A major benefit of the course is the restriction in numbers to ensure hands-on experience, and we also cover a lot of theory informally during the practical sessions.

Our training centre has three Injection Moulding Machines:
Fanuc All Electric Roboshot 100T
Arburg 320c Golden Edition (Hydraulic) 50T ( new)
Demag Ergotech NC4 (Hydraulic) 35T
Krauss Maffei KM50-125c (Hydraulic) 50T

Where possible we restrict Injection Moulding course numbers to just six places using up to four machines. Our courses can be run in-company if required, or we can modify any course to your needs. FETAC certification is included in the course costs - The FETAC approved examination conducted at the end of the course counts as one credit towards our Vocational Certificate in Polymer Processing.

Who Should Attend?
This course is aimed at anyone who wants to get a very comprehensive understanding of the moulding process. The course material has a very practical application with approximately 70% of the time spent on the machines.

Methods of Assessment: 

The assessment at the end of the programme, if successfully completed, will lead to one credit towards a major(compound) award, of which 8 credits are needed in total. Please see How to achieve a QQI major award with FPT. Some of our programmes have assignments as part of the assessment which should be completed by the learner after the programme has finished. Full instructions, time-lines and ongoing guidance will be given by the course tutor. Most assessments are completed during the programme and results will be made available to learners as soon as they have gone through our Quality Assurance procedures and final submission to QQI

Subjects Taught: 

• Good Moulding
• Shop Practice and Safe Operating Procedures
• Analysis of the Moulding Cycle
• Practical Session
• Basic Machine Set Up
• Clamp Unit
• Injection Unit
• Basic Machine Optimisation
• Practical Demonstrations

• Design and Construction
• Cooling Venting
• Balance / Gating / Clamping
• Requirements / Part Design

Plastics Materials:
• Processing of various thermoplastics
• Correct material handling & preparation
• Processing factors relating to thermoplastic materials

Process Control:
• Process variables & how they influence part quality/product consistency
• Selection of correct process parameters
• Screw speed optimisation
• Material and mould temperature selection
• Profile injection speed
• Holding pressure optimisation
• Influence of one processing variable change on other variables
• Practical session on machine
• Optimisation of the moulding process
• Setting for consistency
• Practical optimisation of the moulding machine

• Analysis of mould faults
• Logical troubleshooting
• Practical examples

Course Keywords: 

This programme is a QQI component (minor) award, certified at Level 5 on the national framework of qualifications (

FETAC Code: 

5N3036: Injection Moulding Process Optimisation