LEARN FROM INSTRUCTORSWHO PRACTICEWHAT THEY TEACH

PlasticsEngineering

SPR ING 2012

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 maximizeproductivity, efficiency and innovation in the field of Plastics Engineering.

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

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

For more details and to learn how we can bring coursesonsite to you, contact me at 414-227-3121 ormvedula@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 atDow Chemical Company and StructuralComposites Industries for several years beforejoining UWM in 1997. Dr. Vedula uses his engineering knowledge to identifyprofessional development needs, includingelastomer and plastics technology, electricalengineering, innovation, mechanical andindustrial engineering, and Six Sigma. Inadd ition, he created an Office Lean certificateprogram and has been involved with internalLean training. He currently serves on theBoard of the Society of Plastics EngineersMilwaukee Chapter.

MARCIAGABRIELProgram Managergabrielm@uwm.edu414-227-3378

Marcia Gabriel is responsible for developingeducational programs that focus on sustainabilityfor the School and for the Community. Priorto joining SCE, Marcia spent the past 11years working for Hunzinger ConstructionCompany/Sustainable Building Solutions(Brookfield, Wisconsin), as the Director ofHunzinger Construction University and servedon the Project Management team. Marcia wasnamed Green Educator of the Year in 2008 byWisconsin Builder Magazine.

WiSE Up! The Women in Science & Engineering

(WiSE)

monthly Breakfast Series provides constructive

insight into the issues women face in these fields,

and helps you build a new professional network.

sce-eng.uwm.edu

TABLE OF CONTENTSPlastic Material Selection ............................................................4

Plastic Part Failure Analysis ..........................................................5

Plastic Injection Mold Design Basics ............................................6

Plastic Injection Mold Design-Advanced ......................................7

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

Innovative Solutions for Plastic Part Production ..........................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 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.

COURSE OUTLINE

Instructor: Michael Sepe

Mon.-Wed., Mar. 19-218am-4:30pmFee: $1090*CEUs: 2.0Program No. 4830-8321

*Combo Package: Save $100 per course –Register for both Plastic Material Selectionand Plastic Part Failure Analysis. Fee: $1780

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

See page 10 for more.

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

analysis and its application.

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

PLASTIC PART FAILURE ANALYSISExamine failures in plastic products and address prevention by reviewing the fundamentalsof part and mold design, material selection, processing, product testing and validation.Learn the essential elements of creating a successful plastic product. The tools used toconduct 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 and managers.

COURSE OUTLINE

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

Instructor: Michael Sepe

Thu.-Fri., Mar. 22-238am-4:30pmFee: $890*CEUs: 1.4Program No. 4830-8322

*Combo Package: Save $100 per course –Register for both Plastic Part Failure Analysisand Plastic Material Selection. Fee: $1780

See page 10 for more.

MICHAEL SEPE has over 30 yearsexperience in the plastics industry

with a focus on injection molding and material testing.

6

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.

Instructor: John Vosmeier

Mon.-Wed., Apr. 23-258am-4:30pmFee: $990CEUs: 2.0Program No. 4830-8323

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 tolook 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 cavitiesin the mold and choose the best partingline

- 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

COURSE OUTLINE

See page 10 for more.

JOHN VOSMEIER provides proven methods for success with over 30 years of extensive hands-on

experience in mold design and developm ent.

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

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 solid knowledge of the subject matter.

Instructor: John Vosmeier

Thu.-Fri., Apr. 26-278am-4:30pmFee: $790CEUs: 1.4Program No. 4830-8324

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 Preformance- 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

COURSE OUTLINE

See page 10 for more.

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

a design and consulting firm.

Over the lifetime of the average car,plastic parts save 650 gallons of gas

as a result of the lighter weight.

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 includingthe fundamentals of plastic materials, behavior and selection, engineering design,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., May 14-158am-4:30pmFee: $890CEUs: 1.4 Program No. 4830-8325

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

INNOVATIVE SOLUTIONS FOR PLASTICPART PRODUCTIONLearn to overcome challenges facing the injection molding industry. Evaluate the needsvs. equipment (for injection molding). Present the selection of molds available and criteriafor choosing them. Identify solutions and suggestions for day-to-day issues that arise withthe quality of injection molded parts.

Who Should AttendPlastic part designers, processing engineers, production managers, individuals involvedin production of unique parts, and engineers and managers involved in reducingproduction time while maintaining quality.

Instructor: Nicholas W. Brown

Wed.-Thu., May 16-178am-4:30pmFee: $790CEUs: 2.0Program No. 4830-8326

Introduction & Course Outline Review- Molding process particulars- Selecting an injection machine- Sizing the equipment list to the operation

- Auxiliary equipment needed- Cooling systems

Scientific Injection Molding Principals- Mold construction review (various types)

- Injection mold types and limitations- Selecting the correct design (guidelines)

- Maintaining your injection molds

Product Design IssuesDesigning to Fit the NeedDesigning PitfallsClass Project....Individuals

Problems and SolutionsMachine Problems- What kind of issues can be machine related?

- Injection machine limitations- What are common machine failuresand how to prevent them

- Maintaining your injection machine

Processing / Plastic Part Problems- Common issues (gate blush, flowlines / streaks, hard-to-fill parts)

- Delaminations, over packing, excessive shrinkage, short shots

- Splay / silver streaks, surface blemishes, flash, warpage

- Weak weld lines, bubbles vs. voids, black specks

- Determining root cause & solutionsof defects

Resin problems- Correct vs. incorrect selections- Fillers and additives- Shrinkages- Mechanical properties

Mold problems- Common issues- Preventing those issues in design- Correcting them once they occur- Don't make matters worse by poor decisions

Final Class Project....Groups

Nicholas Brown has over 20 years of injection molding experience–now managing

a 24/7 worldwide operation that averages 358 days of production.

See page 10 for more.

The U.S. plastics industry employsmore than 1 million workers

at over 17,600 plastics facilities.

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

Instructors.Nick Brown has worked in the Injection Molding industry for over20 years. He attributes his unique perspective on molding to the factthat he started his career as a molding technician and has held suchpositions as Process Engineer, Manufacturing Engineer, PlantSuperintendent and Plant Engineer. Working his way through theranks has given him a well-rounded and "hands on" approach toproblem solving. For the past twelve years he has been the MoldingManager for a world wide consumer products company in thedepartment he founded. The company runs a 24/7 operation whichhas averaged 358 days of production per year. An avid student, Nickearned a Bachelor degree in Business in 2000 and recently receivedhis MBA. Nick received the Master Molder 1 and Master Molder 2certifications from RJG in 2000.

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 onmaterial analysis and its application to the solution of productperformance and processing problems. He currently works as anindependent consultant to the industry and provides analyticalservices and assistance in solving design, manufacturing, andmaterial selection problems.

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.

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.

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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.

DirectionsAll programs are held at the UWM School of Continuing Education indowntown Milwaukee, WI: 161 West Wisconsin Ave., Ste. 6000. For directionsvisit sce-directions.uwm.edu. The webpage includes printable PDFs ofcurrent maps, information about parking and public transportation, andother details relevant 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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REGISTRATION

School of Continuing Education 161 W. Wisconsin Ave. Ste. 6000Milwaukee, WI 53203-2602

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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