Course Title

Course Title: Design Guidelines: Copper in Injection Molds

18 Professional Development Hours/1.8 CEUs

Course Description: The Design Guidelines: Copper in Injection Molds course discusses how copper alloys are used in mold components, and the benefits obtained by this use. To differentiate copper from the other mold materials, thermal conductivity and alloy hardness are also discussed The mold cooling section explains how heat is removed from the injection molds. Reasons and processes for plating copper alloys is touched upon, along with several examples of applications using copper alloys.

Overall Course Objectives:

Understand how copper alloys are used in mold components, and the benefits obtained by this use.
Differentiate copper from the other mold materials based upon thermal conductivity and alloy hardness.
Understand heat removal from injection molds.

Course Content:

Lesson 1 - Conveying of Molten Polymer, The Injection Mold

Objectives:

Name three alloys that are typically utilized for the mold components that have contact with plastic, and understand the effect the have on the plastic.

Recognize the advantages when using copper alloy in sprue bushings and runner systems.

Gain knowledge on the nomenclature of the injection mold, and the advantages of using copper alloy in mold lifters, slides, cores and other moving components of the mold.

Lesson 2 - Mold Core, Mold Cavity

Objectives:

Identify types of core construction and recognize methods used to remove heat from the mold core.

Understand mold cooling and cycle time improvements.

Recognize the most common gate types used in injection molding, along with the ideal placement and size of the gate.

Lesson 3 - Mold Components, Mold Cooling

Objectives:

Compare the coefficient of thermal expansion in copper alloys to that of tool steels.

Define friction and recognize the high wear areas of the mold.

Develop an understanding of how temperature control channels are used.

Lesson 4 - Plating of Copper Alloys, Application using Copper Alloys

Objectives:

Identify the two most effective choices for protecting copper alloys, and list some reasons for plating mold components.

List the advantages of using copper alloys for clear blow molded cavities.

Recognize the advantages of many different applications which use copper alloy.

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