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→Certification
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[[Media:Manual_InjectionMolder.pdf|Injection Molding Machine User Manual]]
==Training==
==Training==
====Overview====
====Operation====
The injection molder works by melting plastic pellets within a heated barrel to a specific temperature, and using a ram plunger to force the molten plastic through a nozzle, into a mold cavity.
The injection molder works by melting plastic pellets within a heated barrel to a specific temperature, and using a ram plunger to force the molten plastic through a nozzle, into a mold cavity.
====General Procedure====
====General Procedure====
# Setup
# Setup
## First we have to Preheat the mold. If a hot plate is available, preheat the aluminum mold to prevent plastic cooling too fast by placing the mold on the hot plate and heating to a specific temperature. Temperatures for different plastics can be found in the table below.[[File:...injectionTemperatureChart.png|none|thumb|373x373px]]
## You will need to setup the molding machine using the following steps and charts. Temperatures for different plastics can be found in the table below. Make sure to wear gloves and safety glasses while using this machine.[[File:...injectionTemperatureChart.png|none|thumb|373x373px]] [[File:Temp_Controller.JPG|600px|thumb|none]]
## Next we need to adjust the height by following these steps.
## First we need to adjust the height for the mold being used by following these steps.
### Set the mold clamps to measure the gap.
### Set the mold clamps to measure the gap.
### Loosen the height adjustment bolts on the top holder using a 6mm Allen Wrench.
### Loosen the height adjustment bolts on the top holder using a 6mm Allen Wrench.
### Tighten the upper and lower tension nuts.
### Tighten the upper and lower tension nuts.
# Molding
# Molding
## Now we can starting molding materials!
## Turn on the power switch.
## Make sure the SV value is correct on the temp controller for the type of material you are using. Adjust the temp controller using the setting buttons if the SV value needs adjusting.
## Wait for the PV value to reach the SV value.
## Now add pellets to the feeder.
## Wait several minutes for the pellets to melt. If you want to preheat the mold now is the time.
## You should see a small amount of plastic ooze from the nozzle
## Make sure the mold is clamped tight and the nozzle nipple is aligned with the mold sprue.
## Scrape away any oozing plastic from the nozzle using a screwdriver or similar tool. This helps keep plastic chunks out of the mold.
## With a smooth linear motion push down on the handle and fill the mold.
## Hold pressure on the handle for an extra few seconds. This will help reduce shrinking of the plastic in the mold.
## Retract the handle all of the way to remove the plunger and give access to load more pellets.
## You can now remove the mold and separate the halves.
=====Making a Resin Mold for the Injection Molder=====
The Mold:
* Find/make a 3D model of the object you want to mold.
* Follow the instructions in the linked video to turn the object into a 3d model on SolidWorks:
{{#evu:https://www.youtube.com/watch?v=jm9b_8kYKuQ}}
* Save the SolidWorks file as an STL file.
* Then follow the steps in the maker-hub wiki to print this STL file on the Formlabs resin 3D printer. Make sure to use the HIGH TEMP RESIN in the Formlabs and not another type of resin as this kind is the best for injection molding.
** TIP: Curve the edges of the mold to better fit inside the mold casing
The Aluminum Casing (x2):
* Find a piece of aluminum stock that is larger than one-half of your mold in every dimension.
* Next, cut down the piece using the mill until the aluminum block is somewhere between 1/8”-1/4” larger than the piece of your mold. This will allow a wall of that thickness around your mold.
* Then mill out a cavity in the block of aluminum that is around the size of your mold. This cavity will be for press fitting half of the mold into, but it shouldn’t be too tight or else the mold might break. The depth of this cavity should be the same distance as the thickness of the mold piece, so when press fitted the casing and mold faces are flush.
* Then, drill out a hole at the top of the mold for the spout where the plastic will be injected into.
* The printed mold will then be press fitted into the cavity but be careful not to crack the mold when press fitting.
<gallery mode="packed" heights="300px">
Image:Resin Mold 1.jpg
Image:Resin Mold 2.jpg
Image:Resin Mold 3.jpg
</gallery>
==Safety==
==Safety==
==Certification==
==Certification==
Complete <strong>The Vault - {{PAGENAME}} Module</strong> at the link below to gain access to the {{PAGENAME}}. The Maker Hub Canvas course pertains to all facilities and equipment contained in the Maker Hub; simply complete the quizzes for the facilities/equipment you wish to use in the Maker Hub. Please email <span style="color:blue">makerhub@georgefox.edu</span> if you have any questions.
[https://foxtale.georgefox.edu/moodle/course/view.php?id=31709 Foxtale Course]
[https://georgefox.instructure.com/enroll/G7CTPX Maker Hub Canvas Course]
==Troubleshooting==
==Troubleshooting==