Injection molding is one of the most versatile and important operations for mass production of complex plastic parts with excellent dimensional tolerance. Among all the polymer-processing methods, injection molding accounts for 32% by weight of all the polymeric material processed. This course covers all the major aspects of injection molding as outlined below, with emphases on design, processing, process physics, computer-aided engineering (CAE), troubleshooting, and advanced molding processes. Lectures also include video tapes, case studies, field trip, independent research project with presentation, and hands-on sessions of using CAE tools to provide students with "real-world" experiences and help them develop logical thinking, analyzing and problem-solving skills.

Outline:

Introduction of Injection Molding (Process Evolution, Significance, and Outlook)

Review of Thermoplastic and Thermosetting Materials

Machine Components and Operation

Process Cycle

Process Physics

Part Design for Injection Molding

Mold Design and Tooling

Application of Computer-aided Engineering (CAE)

Troubleshooting

Advanced Molding Processes (Co-Injection, Gas-Assisted, Injection/Compression, Microchip Encapsulation, etc.)