Tutorial Abstracts
Tutorial Sessions
Use these links to jump to a specific tutorial abstract below.
Wednesday Tutorials
- Injection Molding Set-Up & Documentation
- Application of DMA and other Thermal Analysis Techniques
- Application of Mold Filling Analysis
- Improve Your Negotiation Skills!
- Ultrasonic Welding 101
- Executive Overview of Validation for Plastics Processors
- Rheology of Thermoplastic and Thermosetting Polymers
- Introduction to LSR Injection Molding
Thursday Tutorials
- Injection Molding Troubleshooting
- 3D Printing 101
- Alternative Processes (Not All Parts Are Injection Molded)
- Material Selection Overview
- Considerations for Post-Molding Automation
- Troubleshooting Injection Molding Issues Using Flow Group Methodologies
- Plastic in the Great Lakes and Beyond - What to Do with the Data?
Injection Molding Set-Up & Documentation, Brad Johnson, Penn State Behrend
Go through a hands-on process set-up using a proven methodology for setting up an injection molding process on a closed-loop controlled machine. The two stages of this method refer to the injection portion of the set-up, with the first stage controlled by velocity and the second stage controlled by pressure. During this tutorial you will be walked through the steps of the set-up, learn what types of problems to look for along the way, and see why the various process settings are made.
Application of DMA and other Thermal Analysis Techniques, Alicyn Rhoades & Jason Williams, Penn State Behrend
Dynamic Mechanical Analysis (DMA) data makes it possible for engineers and designers to understand the important aspects of a plastic material’s behavior over an extended service life. See how data is generated and learn about practical applications. In addition, a number of other thermal analysis techniques will be reviewed.
Application of Mold Filling Analysis, Matt Jaworski, Joe Huegel, and Mason Myers, Autodesk Moldflow
This workshop shows the advantages of using mold-filling analysis during the design phase to reduce potential problems and create a more robust design. There will be demonstrations of the use of the software and the methodologies used to solve problems. How to interpret the results of the simulation also will be discussed.
Improve Your Negotiation Skills!, Mike Brown, Penn State Behrend
Knowing how to negotiate effectively can help you and your organization succeed. In this session, you will learn some of the basics of effective negotiation. You will also have an opportunity to practice what you've learned by taking part in a negotiation exercise.
Ultrasonic Welding 101, Donald Patten and Brad Rogers, MS Plastic Welders
This tutorial will cover topics to consider when evaluating ultrasonic welding as a joining method for thermoplastics. These topics will include the following:
Ultrasonic Plastic Welding Basic Terminology / Overview
- Definition of U/S Welding
- Weldable Materials
- Ultrasonic Frequencies and Modes of Vibration
- Ultrasonic Components
- Ultrasonic Machine Concepts
- Ultrasonic Weld Cycle Overview
Basics of Device Manufacturing with Ultrasonic Plastic Welding
- Markets – Where Used
- Focus on Materials
- Sonotrodes
- Joint Design / Part Design
- Joining Techniques
- Process Control
Executive Overview of Validation for Plastics Processors, Sean Tucker, Intuitive
This session will focus on the key elements involved with Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) as applicable to molding operations. An overview of process development and other requirements to successfully validate the process, after receiving a finalized product design, will be reviewed.
Injection Molding Troubleshooting, Brian Young, Penn State Behrend
This tutorial will provide hands-on experience in solving common molding problems in the processing lab. In the classroom, the theory behind the solutions and problem-solving strategies will be discussed.
3D Printing 101, Eli Thompson and Michael Gibilterra, Penn State Behrend’s Innovation Commons Staff
An introduction to the 3D printing process. This workshop will provide the attendee with a background of 3D printing, its operating principals, and a hands-on experience with the technology. Attendees will get to carry a CAD file through all the steps needed for exporting, slicing, and building a 3D printing part. Parts will be constructed on several of the entry-level 3D printers in our laboratories.
Alternative Processes (Not All Parts Are Injection Molded), Jon Meckley, Penn State Behrend
This workshop offers you an overview of blow molding, thermoforming, extrusion, rotational molding, and thermoset processes. The vocabulary and basic principles of each process, molds, and design will be covered. There will be time in the lab to demonstrate some of the processes.
Material Selection Overview, Gary Smith, Penn State Behrend
Basic polymer fundamentals will be introduced with a strong correlation to structure property relationships. An overview will be given of homopolymers, copolymers, morphology, molecular weight, and viscosity. Structure property relationships based on polymer chemistry (in a non-intimidating way!) will focus on “why” the materials perform like they do. Polymer fundamentals will be incorporated into a product selection process and failure analysis.
Considerations for Post-Molding Automation, Ben Mintz, Neff Automation
Webster’s defines automation as an automatically controlled operation of an apparatus, process, or system by mechanical or electronic devices that take the place of human labor.
Traditionally automation was designed for large companies making a very high volume of parts or assemblies. Due to the growing skills gap in small- to medium-sized manufacturers, these companies now more than ever are looking for solutions. Fortunately, the advancement of technology, specifically in the areas of short-run and low-volume applications, has reached a point that makes automation a viable solution, often with ROIs of less than 18 months.
The vetting out and adoption of this technology has been slowed based on outdated assumptions about applying automation into lower volume manufacturing. The key to enabling the proper application of these technologies is via education and shared lessons learned from similar companies who have already begun their journey to taking control and resolving the employment and skills gap.
Presentation Outline
- A review of traditional automation (cages, floor space, 6-month runs of a single SKU)
- What automation looks like today (mobile robots, no guarding, easy to reprogram)
- Highlights from a few of the major technologies that have enabled this revolution
- Addressing Labor Shortages - Collative Robots, Universal Robots
- Addressing Quality - Machine Vision, Cognex
- Addressing Part Presentation - Asryil/PickIt
- Preventive Maintenance - I/O Link, Balluff
- Application Specific Tooling – PIAB
- How to get started, a brief discussion on self-integration vs using machine builders / LEAN Manufacturing
Troubleshooting Injection Molding Issues Using Flow Group Methodologies, Dave Rose, American Injection Molding Institute, and Travis Belz, Beaumont Technologies
Diagnosing part quality variations in injection molding can be a daunting task. By understanding how “flow groups” are developed and coupled with basic principles of pressure drop during molding, troubleshooting can become faster and more effective. The application of flow groups can benefit a variety of operations in molding facility, including processing, mold maintenance, and quality control. This tutorial will provide attendees with an understanding of the fundamental flow characteristics that create these “Flow Groups” along with numerous troubleshooting examples and tips. Attendees will spend time split between a classroom lecture and working with a diagnostic software (Mold Genius).
Rheology of Thermoplastic and Thermosetting Polymers, Dave Rhoades, Penn State Behrend
This tutorial will be focused on understanding the practical and fundamental aspects of rheology of different polymeric materials, such as thermoplastics, thermosets, gels, semi-crystalline polymers, and polymer blends. The tutorial will begin with a short presentation on rheology fundamentals followed by typical rheological measurements using rotational and capillary rheometers. Data analysis and non-linear regression for theoretical fitting also will be considered in this tutorial.
Plastic Pollution in the Great Lakes and Beyond - What to Do with the Data?, Alicyn Rhoades, Penn State Behrend
In the past year, the problem of plastic pollution has become one of the most visible and hot-button issues promoted by the mainstream media. Environmental science data shows a significant amount of plastic pollution found in freshwater lakes is in pellet form—indicating industrial waste may be the source. This tutorial will be delivered in three sections. First, "What are the facts about freshwater and ocean plastic pollution, and how did the environmental scientists determine these facts?" Second, "Brainstorming an industry response to the mainstream media's coverage of the plastics pollution problem" and finally "Strategies for reducing industrial waste." In the third section, strategies include wastewater management as well as an overview of new and future biodegradable plastic options.
Introduction to LSR Injection Molding, Dana King, Kipe Molds; Eric Bishop, Robert Jovingo, Kevin Barbee, Shin-Etsu; Mike Pelletier, Graco
This workshop will provide valuable information for anyone interested in using liquid silicone rubber parts or the manufacturing of the parts. An overview will be provided on the materials available, the features needed for the molds, the molding machine, and the feeding systems of the materials to the molding machine. The workshop will also include a demo of the LSR molding process.