LEARN FROM INSTRUCTORSWHO PRACTICEWHAT THEY TEACH

PlasticsEngineering

FALL 2011

C o n t i n u i n g E d u c a t i o n

SCE-PLASTICS.UWM.EDU

Results-Driven Courseswith Real-Life Engineers

Welcome to the UWM School of Continuing Education (SCE), where you’ll gain the knowledge to maximize productivity, efficiency and innovation in the field of Plastics Engineering.

You’ll use your new skills to make an immediate impact at your job. How do we know?Because our instructors use them too!

SCE instructors are real-life engineers seasoned with real-world experience in the field they teach. From basic part to advanced mold design, they provide you with a range of strategies proven for success.

For more details and to learn how we can bring courses onsite to you, contact me at 414-227-3121 or mvedula@uwm.edu.

Sincerely,

Murali Vedula, Engineering Program DirectorUWM School of Continuing Education • sce-eng.uwm.edu

MURALIVEDULAProgram Directormvedula@uwm.edu 414-227-3121

Dr. Murali Vedula worked in engineering at DowChemical Company and Structural CompositesIndustries for several years before joining UWM in1997. Dr. Vedula uses his engineering knowledgeto identify professional development needs,including elastomer and plastics technology,electrical engineering, innovation, mechanical andindustrial engineering, and Six Sigma. In add ition,he created an Office Lean certificate program andhas been involved with internal Lean training. Hecurrently serves on the Board of the Society ofPlastics Engineers Milwaukee Chapter.

MARCIAGABRIELProgram Managergabrielm@uwm.edu414-227-3378

Marcia Gabriel is responsible for developingeducational programs that focus on sustainability forthe School and for the Community. Prior to joiningSCE, Marcia spent the past 11 years working forHunzinger Construction Company/SustainableBuilding Solutions (Brookfield, Wisconsin), as theDirector of Hunzinger Construction Universityand served on the Project Management team.Marcia was named Green Educator of the Year in2008 by Wisconsin Builder Magazine.

DEBRAO’NEILProgram Associate oneil@uwm.edu414-227-3180

Debra O’Neil has been with the School ofContinuing Education for over15 years, nine ofwhich she was a program associate supportingpublic and corporate Engineering programs. Sheassists with the coordination of course scheduling,materials assembly, program content, marketing,inquiries and billing. She is customer serviceoriented and enjoys working with programparticipants.

TABLE OF CONTENTSPlastics Technology

Plastic Injection Mold Design Basics ............................................4

Plastic Injection Mold Design Advanced ......................................5

Plastic Material Selection ............................................................6

Plastic Part Failure Analysis ..........................................................7

Designing Plastic Parts for the Injection Molding Process ............8

Quality / Business Process Improvement

Six Sigma Black Belt ....................................................................9

Instructors ....................................................................................10General Information ..................................................................11Onsite Training ............................................................................Back Cover

"THE PROFESSOR WASTHE BEST ONE I'VEEVER HAD FOR A SEMINAR OR TRAINING CLASS.

I'M DEFINITELY GOINGTO COME BACK TO UW-MILWAUKEE FOR FUTURECLASSES."

– Mary J. Glander,Task Force Tips

Learn howto earn a

Plastics TechnologyCertificate 414-227-3121

or visit

sce-plastics.uwm.edu

4

PLASTIC INJECTION MOLD DESIGN BASICSGain a thorough understanding of injection mold design fundamentals. This practicalcourse gives those involved with injection molds a comprehensive look at design anddemonstrates how to contribute to the success of projects. It offers a unique blend of verydetailed mold design concepts set forth in the context of the design process as a whole.On the final day you participate in an actual design project.

Who Should AttendAnyone responsible for procuring, evaluating, building or designing injection mold tools,including tooling engineers, buyers, toolmakers, mold designers, product designers,managers and molders.

COURSE OUTLINE

Plastics.

Instructor: Jim Walsh

Mon.-Wed., Aug. 22-248am-4:30pmFee: $1090CEUs: 2.0Program No. 4830-8301

Introduction and OverviewThe Anatomy of a Mold

- Mold Types • Stripper plate molds • Unscrewing molds • Quick change molds • Hot runner molds • Shuttle molds- Basic Mold Construction • Use and placement of bolts

and dowels • Major suppliers and differences

between them • How to specify and order

mold bases and components- Common Components

and Their Function • Leader pins, return pins, support

pillars, rest buttons, etc.

The Molding Press- How the mold interfaces with

the press- Horizontal and vertical clamp- Shuttle and rotary presses

Plastic Resin Fundamentals- Amorphous and semi-crystalline

- Basic properties and how they affect the mold design

Shrink- How to use shrink to your advantage- Factors that affect shrink and warp

Plastic Product Design Fundamentals- Common errors- What the mold designer needs to look

for in a product design

Sprue, Runner and Gate- Common gate design errors- Runner sizing guidelines- Runner pullers

Ejection- Determining ejector place- Pin orientation methods- Knock-out patterns- Return pins and springs

Basic Mold Inserting- Solid vs. split construction- Criteria for inserting

Slides and Lifters- A thorough look at how

to mold undercuts- Typical slide and lifter construction- Mechanical vs. hydraulic

Cavity Layout- How to efficiently “place“ the cavities in

the mold and choose the best parting line- How it affects runners, ejection

and gates

Cooling- The economic effect of cooling design- General rules for waterline placement- Thermal conductivity of various

tool steels

Venting- Venting of runners- How venting affects the molded part- Why this should NOT be overlooked

Mold Steel - What to look for in a mold steel- A discussion of steel hardness- Alternate materials used in molds

Plating and Polishing- A selection chart for mold coatings- When and why to use plating

Mold Design from a Project PerspectiveStudent Design Projects

- Students will be split into groups to work on actual design projects

JIM WALSH provides proven methods for success with over 30 years of extensive hands-on

experience in mold design and developm

See page 10 for more.

sce-plastics.uwm.edu 414-227-3121 5

PLASTIC INJECTION MOLD DESIGN ADVANCEDYou’ve got the basics, now it’s time to move to the next level. Examine the inner workingsof injection molds, including cost saving techniques. You are encouraged to bring currentreal-life problems to be addressed.

Who Should AttendMold designers, tooling engineers and toolmakers, product designers, buyers, molders and managers.

Requirements: Completion of Plastic Injection Mold Design Basics or a solidknowledge of the subject matter.

COURSE OUTLINE

Introduction and Overview- Course objectives

Molding Surface Tolerances- The various fits in a typical mold- The tolerances that should be maintained- How the product tolerances affect tool tolerances- How it affects mold cost

Mold Strength and Performance- Understanding the forces acting against a mold- Various calculations- Designing for strength and longevity

Mold Alignment and Interlocking- Various methods of insuring mold alignment- Balancing of forces in a mold- Core shift causes and fixes- How it affects mold longevity

Advanced Parting Line and Shut-off Development- A detailed look at shut-off designs- Contoured and stepped parting lines- Common product design errors that complicate parting lines- Examples of complex parting lines

Advanced Slide and Lifter Design- When to use a lifter instead of a slide- Methods of slide actuation- A look at the forces involved- Proper heel block and gib design

- The use of springs with slides- How and when to delay slides- Dual action slides- Designing slides for low maintenance- Determining slide travel- Alternate methods of molding undercuts- Collapsible and expandable cores

Advanced Cavity and Core Inserting- A thorough look at every aspect of inserting- Criteria for deciding whether or not to insert- Pins and other round inserts- Inserting slides and lifters- Laminated and gate inserts- The economics of inserting- Assembling of inserts- Quick change inserts

3D Modeling and Mold Design- Improving translation between CAD systems- General problems with CAD exchange- Tips and tricks- Translation options

Mold Monitoring- Pressure transducers- Thermocouples- Proximity and limit switches- Vision systems

Instructor: John Vosmeier

Thu.-Fri., Aug. 25-268am-4:30pmFee: $890CEUs: 1.4Program No. 4830-8302

JOHN VOSMEIER has first-hand experience withdesign through owning DeJohn Innovative Plastics –

a design and consulting firm.

6

PLASTIC MATERIAL SELECTIONLearn about the various factors involved in selecting a plastic material for your application.Discover plastic processing considerations that will help you design consistent and reliableparts. Understand how to avoid mistakes in molding through a better appreciation ofplastic properties.

Who Should AttendMold designers, tooling engineers and toolmakers, product designers, buyers, molders and managers.

Instructor: Michael Sepe

Mon.-Wed., Sept. 26-28, 8am-4:30pmFee: $1090*CEUs: 2.0Program No. 4830-8306

*Enroll in Plastic Part Failure Analysis& receive a $100 discount

Defining the Fundamentals that Determine Plastic Properties

- Molecular weight – the foundation of polymer technology • The relationship to viscosity • The relationship to properties • New technologies that change the rules- Methods of Polymerization – addition and

condensation polymers- Polarity – why nylons absorb water and polyethylenes

absorb gasoline- Amorphous and semi-crystalline polymers • Detecting the presence of crystalline structure • Effects on processing and properties • The role of polymer blends

Property Evaluations – Short Term- Tensile, flexural, and compressive properties- Impact properties – various methods of measurement- Thermal properties- Other properties – flammability, wear resistance,

optical, etc.- The role of material property databases

and selection utilities

Property Evaluations – Long Term- Effects of temperature- Chemical resistance – effects of temperature and time- Creep resistance, stress relations and fatigue- The fundamental equivalence of temperature and time- Environment stress crack resistance- Radiation resistance – weathering, ultraviolet, sterilization

Property Modifications- Fillers and reinforcements- Impact modifiers- Colorants- Stabilizers

Establishing the Cost / Performance Profile- Defining application requirements- Matching requirements of a cost effective material family- Design properties vs. inherent properties- Designing for manufacturing- The role of simulation

Selecting a Material SupplierCase Studies – Successes and Failures

COURSE OUTLINE

MICHAEL SEPE writes a monthly article for Injection Molding Magazine on material

analysis and its application.

See page 10 for more.

sce-plastics.uwm.edu 414-227-3121 7

PLASTIC PART FAILURE ANALYSISThis course examines failures in plastic products and addresses prevention from thestandpoint of the fundamentals of part and mold design, material selection, processing,product testing and validation. Learn the essential elements of creating a successful plasticproduct. Analyze material selection, design and manufacturing principles. The tools usedto conduct failure analysis are reviewed with an emphasis on practical application and astandard approach to methodology.

Who Should AttendMold designers, tooling engineers and toolmakers, product designers, buyers, molders andmanagers.

Instructor: Michael Sepe

Thu.-Fri., Sept. 29-30, 8am-4:30pmFee: $890*CEUs: 1.4Program No. 4830-8307

*Enroll in Plastic Material Selection& receive a $100 discount

Elements of a Successful Plastic Product- Part design- Mold design- Material selection- Processing

Principles of Plastic Part Design- Nominal walls- Ribs and other projections- Holes and other depressions- Designing for manufacturing and assembly (DFMA)- Design properties versus inherent properties of materials

Mold Design Considerations- Mold steel selection- Managing polymer flow in the mold – runners and gates- Cavitation and the effect on balanced flow

- The economics of cavitation- Hot runners versus conventional cold runners- Mold temperature control- Draft angles and ejection

Material Selection- Defining the application environment – time, temperature,stresses- Amorphous and semi-crystalline polymers- The importance of molecular weight- Structural choices within a polymer family- Property modifiers and additives- Regulatory considerations – UL, NSF, FDA

COURSE OUTLINE

MICHAEL SEPE has over 30 yearsexperience in the plastics industry

with a focus on injection molding and material testing.

See page 10 for more.

8

DESIGNING PLASTIC PARTS FOR THE INJECTION MOLDING PROCESSTo design a high quality injection molded part, the designer must select an appropriateplastic material formulation, develop a functional design and work within themanufacturing limitations associated with the injection molding process. Get acomprehensive overview of plastic part design for the injection molding process. Thiscourse covers the fundamentals of plastic materials, behavior and selection, engineeringdesign, manufacturing considerations and assembly methods.

Who Should AttendEngineers and designers who are accustomed to working with metals and are faced withmetal to plastic concerns.

Requirements: You should have some knowledge of plastic materials, injection molding and engineering principles, although the basics are introduced.

Instructor: Nick Schott

Mon.-Tue., Nov. 7-88am-4:30pmFee: $890CEUs: 1.4 Program No. 4830-8303

An Introduction to Plastic Materials- Historical development- Fundamental concepts- Molecular weight- Repeat unit structure- Morphology- Effect of additives- Mechanical property overview- Flow property overview- Advantages of plastic materials- Limitations of plastic materials

Review of Injection Molding EquipmentReview of the Injection Molding ProcessReview of Injection MoldsDesign Considerations for Injection Molded Parts

- Mold filling considerations- Effect of gate location and type- Molecular and fiber orientation- Mold filling pressure drop

- Flow leaders and flow hesitation- Mold filling simulations- Runner balancing and family molds- Weld or knit lines- Shrinkage and warpage considerations- Part Ejection considerations

Mechanical Behavior of Plastic MaterialsApproaching Plastic Product Development

- Establishing end use requirements- Conceptual design- Initial candidate material selection procedures- Design based upon the materials selected- Final materials selection- Manufacturing related design modifications- Prototyping and testing- Production tooling and manufacturing- Plastic part prototyping techniques- Assembly techniques for injection molded parts

COURSE OUTLINE

NICK SCHOTT understands a range of plastics processes as a worldwide lecturer, researcher

and instructor of product design and injection molding.

See page 10 for more.

COURSE OUTLINE

sce-plastics.uwm.edu 414-227-3121 9

SIX SIGMA BLACK BELTSix Sigma is a highly disciplined improvement methodology that helps organizationsachieve optimal performance in all operations. Learn methods to identify how many“defects” you have in a process and systematically determine how to reduce them to get asclose to zero defect as possible.

Who Should AttendAnyone wanting to improve quality, identify and reduce sources of variation and reducethe rate of non-conformance in products or services.

Instructor: Davis R. Bothe

Module I Tue.-Thu., Sept. 13-158am-4:30pmFee: $1295 • CEUs: 2.0Program No. 4830-8101

Module II Tue.-Wed., Oct. 4-58am-4:30pmFee: $1195 • CEUs: 1.4Program No. 4830-8102

Module III Tue.-Wed., Oct. 25-268am-4:30pmFee: $1195 • CEUs: 1.4Program No. 4830-8103

Module IV Tue.-Thu., Nov. 15-178am-4:30pmFee: $1295 • CEUs: 2.0Program No. 4830-8104

Quality.

MODULE IDefine & Measure

- Overview of Process ImprovementStrategies

- Why Six Sigma? The DMAIC (Define, Measure, Analyze, Improve,Control) Roadmap

- Roles of Champions, Master BlackBelts, and Black Belts

- Process mapping – flowcharts- Data collection and sampling

techniques- Basic statistics –

location versus variation- Control charges –

variable and attribute- Control charts for short

production runs- Subgroup statistics versus

process parameters- Rationale for the 1.5σ symbol

MODULE IIMeasure & Analyze

- Gage capability studies- Estimating process parameters- Short- versus long-term variation- Process and machine capability studies- Converting process performance

to a σ level- Effect of the 1.5σ shift on capability- Dealing with non-normal

distribution- Rolled throughput yield

MODULE IIIAnalyze & Improve

- Check sheets and matrix diagrams- Multi-vari analysis for families

of variation- Component swapping for large

assemblies- Brainstorming and cause-and-effect

diagrams- Multi-voting and decision-making

by consensus- Regression analysis and scatter

diagrams- Comparison testing between

“good” and “bad” parts- Analysis of means (ANOM)

MODULE IVImprove & Control

- Hypothesis testing and confidence intervals

- Analysis of variance (ANOVA)- Developing feasible solutions- Solution FMEAs and pilot studies- Mistake proofing – poka-yoke- Advanced control charting concepts- Corrective action plans –

work instruction- Preserving the process

knowledge gained- Kaizen for continuous improvement

Davis R. Bothebrings an impressive

resume, having workedfor NASA, GM and

currently at the International QualityInstitute.

See page 10 for more.

10 sce-plastics.uwm.edu 414-227-3121

Instructors.

Plastics.Michael Sepe brings over 30 years of experience in the plasticsindustry, focused on injection molding and material testing. Hiswork includes hands-on plant experience coupled with businessmanagement at several organizational levels. His primary interestsinvolve the integration of process technology and material testingand analysis to competitively produce high quality products. Heteaches public courses on these subjects at several universities andwrites a monthly article for Injection Molding Magazine on materialanalysis and its application to the solution of product performanceand processing problems. He currently works as an independentconsultant to the industry and provides analytical services andassistance in solving design, manufacturing, and material selectionproblems.

Nick R. Schott completed his B.S. in chemical engineering at UCBerkeley and then went on for an M.S. and Ph.D. in chemicalengineering at the University of Arizona. Professor Schott has beenat the University of Massachusetts Lowell for the past 32 years. Hehas taught courses in plastics product design, plastics injection molddesign, processing and process control. He is an active researcherand a worldwide lecturer on these subjects. Professor Schott wasnamed a fellow of the SPE in 1986 and is a founding member of theSPE Product Design and Development Division. He is an editor ofvarious books and has authored or co-authored numerous papersin the field of plastics engineering.

John Vosmeier has worked as a design manager, senior toolingengineer, senior mold designer and is currently the tooling managerfor a consumer products company purchasing molds in the U.S. andworldwide. He has worked with custom and proprietary moldersover the years as well as owning DeJohn Innovative Plastics, a designand consulting firm since 1987. The business specializes in programdevelopment of injection molds and plastic products. Mr. Vosmeierhas worked in the U.S. as well as Canada, Portugal, Mexico, Taiwan,Hong Kong and China. His extensive travels over the years havegiven him the vehicle needed to accumulate a vast amount ofknowledge and information which he uses to construct curriculum.He holds a degree in tool engineering technology, is a seniormember of SPE and since 1995, he has been very active indeveloping new educational curriculum for the plastics industry.

Jim Walsh has been involved with injection mold engineering for30 years and has extensive hands on experience in all aspects of themold design and development process. Having worked for manyyears as a mold designer, he has hundreds of successful mold designprojects to his credit. His background ranges from small, veryintricate molds for the automotive and electronic connectorindustries to larger molds for consumer products. During his career,Mr. Walsh has held positions of senior mold designer, engineeringmanager, and is currently a senior plastics/ tooling engineer in theautomotive industry and an independent consultant.

Quality.Davis R. Bothe has over 27 years of experience working, teachingand consulting in the field of process improvement. His credentialsinclude: ASQ Fellow, IQI certified Master Black Belt, ASQ certifiedQuality Engineer, ASQ certified Reliability Engineer, member ofthe US Technical Advisory Group to the ISO Technical Committee69 on Applications of Statistical Methods, B. S. in appliedmathematics and physics, and a Master’s degree in businessadministration. He is author of the quality improvement books"Industrial Problem Solving," "Measuring Process Capability," and"Reducing Process Variation." He is listed in the first edition of "TheInternational Who's Who in Quality." Mr. Bothe has worked atNASA, General Motors, Eastern Michigan University and currentlyserves as the director of Quality Improvement for the InternationalQuality Institute.

sce-plastics.uwm.edu 414-227-3121 11

General Information.

TODAY’S WORKPLACE IS CHANGING RAPIDLY.ARE YOU PREPARED?

TODAY’S WORKPLACE IS CHANGING RAPIDLY.ARE YOU PREPARED?

With rapid globalization, technology advancements and demographic shifts, today’s workplace is constantly evolving.Visit the new Center for the Study of the Workplace (CSW)at StudyofWork.com where leaders from the business andacademic worlds educate you on the latest transformations.

• Gain insight from academic scholars • Analyze professional perspectives from real-world experts• Connect with a global community of change-makers• Join the conversation:

Comment Discuss Participate Follow Shareon Video on Blogs in Polls News Feeds Insights

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TODAY’S WORKPLACE IS CHANGING RAPIDLY.ARE YOU PREPARED?

Check back often for updated discussion topics!

FeeThe fee includes program materials, continental breakfast, lunch and breaks.Lodging and other meals are not included.

LodgingYou may make your own lodging arrangement at the facility of your choice.Hotel information will be mailed with your enrollment confirmation.

CancellationsCancellations received less than seven days before the start of the course willbe subject to a late cancellation fee. You may enroll a substitute at any time beforethe course starts, or you may apply the enrollment fee to a future course.

In the event the School cancels a class, we will reschedule, refund fees orapply the fee payment to any other School of Continuing Educationengineering program offered in the next 12 months. Liability of cancellationis specifically limited to the amount of the pre-paid class fee and excludes anyincidental or consequential damages.

DirectionsFor the latest information on getting here visit sce-directions.uwm.edu. Thewebpage includes access to printable color PDFs of current maps,information about parking and public transportation, and other detailsrelevant to our location.

Continuing Education Units (CEUs)All programs in this catalog carry CEUs – a means of recognizing andrecording satisfactory participation in nondegree programs. One CEU isawarded for each 10 contact hours (or equivalent) in an organized continuingeducation experience. All CEUs earned through the University ofWisconsin–Milwaukee School of Continuing Education noncredit programsbecome a part of your permanent record.

For Further InformationContact Murali Vedula at 414-227-3121 or mvedula@uwm.edu.

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PhoneMon.-Fri., 8am-5pm Central800-222-3623 (toll free)414-227-3200 (local)

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ONSITE TRAINING Capitalize on our CapabilitiesAny program can be designed to meet your organization's unique and specificemployee development needs. Onsite training helps you:

Contain Costs by eliminating or reducing travel, food and lodging expenses.

Maximize Convenience by choosing your optimal dates, times and location.

Save Time with staff spending fewer hours away from work.

Build Teamwork through group brainstorming and shared learning experiences.

Custom Tailor Content to your needs to accomplish specific organizationalobjectives. Or, use the curriculum as-is.

For more information, contact Murali Vedula at 414-227-3121 or mvedula@uwm.edu.

SCE-CUSTOMIZED.UWM.EDU