ENG08038 2019 Advanced Polymer Processing and Analysis

General Details

Full Title
Advanced Polymer Processing and Analysis
Transcript Title
Advanced Polymer Processing an
N/A %
Subject Area
ENG - Engineering
MECT - Mechatronics
08 - NFQ Level 8
05 - 05 Credits
Start Term
2019 - Full Academic Year 2019-20
End Term
9999 - The End of Time
Brian Golden, David Mulligan
Programme Membership
SG_EPOLY_K08 201900 Bachelor of Engineering (Honours) in Polymer Processing SG_EPOLP_K08 202200 Bachelor of Engineering (Honours) in Polymer Process Engineering

This module will provide the student with a comprehensive knowledge of the principles of operation, construction and layout of equipment used in the melt processing of polymeric materials. The students will become proficient in the application of the principles of scientific moulding and its use in injection mould design and process improvement.


Learning Outcomes

On completion of this module the learner will/should be able to;


Demonstrate an understanding of the theory, concepts and methods and gain practical application in relation to the injection moulding process.


Analyse key factors that affect the quality and performance of polymer extrusion process.


Inform new designs based on feedback and analysis of injection mould analysis.


Optimise the design and production parameters of an injection mould machine based on analysis an understanding of the historic faults.


Develop a continual improvement system based on evidence to a polymer processes.


Demonstrate a detailed of knowledge and understanding of mould flow analysis.

Teaching and Learning Strategies

Lectures, Tutorials, Handouts and Exercises

Visit to a moulding shop/toolroom to examine moulding machines and moulds.

Application packages, videos and multimedia presentations.

Injection moulding laboratory.

Module Assessment Strategies

End of Year Exam

Project Work

Repeat Assessments

End of Year Exam

Project Work

Indicative Syllabus

Injection Moulding: Construction of machines and types available, hydraulic, electric and hybrid systems. Multi shot systems and micro machines. Types of mould locking systems and tie bar less machines. Screw designs. Nozzle shut-off designs. Moulding cycle Overview of injection moulding non standard materials such as elastomers and thermosets. The effects of moulding conditions and process variables on products, e.g. shrinkage and orientation. Systematic approach to correction of moulding faults. Heating and cooling requirements. EUROMAP specifications and standards; Machine Safety: Requirements and types of safety mechanisms.

Scientific Moulding: Scientific Moulding will involve the design of experiments work and the information flow from this to key design features and process improvements.  

Injection mould design: Basic mould construction

Feed systems: Sprue, Runner and gate systems, including valve-gating. Runner profiles and freeze characteristics, Gate types, size and choice of gating position. Surface vs submarine gates. Runner balancing. Hot runner / insulated runner systems.
Cooling channel design, size and layout. Heat transfer requirements.
Venting: Role of venting, choice of vent location, problems with poor venting.

Mould Analysis:

Pressure Drops in Mould: Calculation of pressure drops across primary, secondary, and tertiary runner; Runner design, including runner balance; Pressure build-up in cavity; Design of runners for two and three plate moulds. Discuss the advantages and disadvantages of both hot runner and insulated runner moulds.

Rheology of Polymers: Newtonian and Non-Newtonian liquids pseudoplastic behaviour; Pressure-Volume-Temperature (PVT) curves ; effects of shear and shear rates on polymers; Use of viscosity and shear rates curves; Factors affecting viscosity; Applications of Rheological Data; Application of rheological properties to moulding conditions.

Plastic flow analysis package: Moulding filling application e.g. MoldFlow. Factors affecting filling, cooling characteristics, warp analysis, effects of gate position, viscosity affects. 

Coursework & Assessment Breakdown

Coursework & Continuous Assessment
40 %
End of Semester / Year Formal Exam
60 %

Coursework Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Injection Moulding Practical Assignment 20 % Week 10 1
2 Mould Flow Analysis Continuous Assessment Project 20 % Week 12 6

End of Semester / Year Assessment

Title Type Form Percent Week Learning Outcomes Assessed
1 Exam Final Exam Assessment 60 % End of Semester 1,2,3,4,5

Full Time Mode Workload

Type Location Description Hours Frequency Avg Workload
Lecture Lecture Theatre Presentation of Module Material 3 Weekly 3.00
Laboratory Practical Engineering Laboratory Laboratory 2 Weekly 2.00
Total Full Time Average Weekly Learner Contact Time 5.00 Hours

Required & Recommended Book List

Required Reading
2013-09 Moulding Masterclass
ISBN 1906479119 ISBN-13 9781906479114

Moulding Masterclass is a compilation of technical articles by plastics injection moulding industry expert John Goff, originally written for magazine publication between October 2009 and July 2013. According to the author, injection moulding processes are frequently developed in the early stages of a product's launch and never revisited. Particularly in today's challenging economic climate where manufacturing costs need to be minimised, it is more important than ever that time is devoted to process optimisation. This collection of 32 articles takes the reader through many aspects of the injection moulding process, from the influence of screw design and speed on melt plasticization, flow and shot consistency, through injection and holding time and pressure, gate sizing, runner systems, mould cooling, clamp forces, systematic process control and more. Each discussion combines theory with recommendations and practical examples seen in diverse manufacturing environments. John Goff has almost 40 years' experience of injection moulding and has seen all sides of the process, having been a senior university lecturer, process engineering manager, consultant and trainer. He has written numerous books and articles, presenting complex technical information in a simple, coherent fashion.

Module Resources

Non ISBN Literary Resources

Injection Moulding Machines, Johannaber, Hanser, 2007

Injection Molding Handkbook: The Complete Molding Operation, Rosato, Chapman & Hall, 1995

Injection Moulding Handbook, Rosato, Springer Science & Business Media 2012

Plastics Extrusion Technology, Hensen, Hanser, 1997

Polymer Extrusion, Rauwendaal, Hanser, 2014

Extrusion Processing Data, Alberto Naranjo C., Maria del Pilar Noriega E., Juan Diego Sierra M., Juan Rodrigo Sanz., Hanser, 2001

Materials and Processes in Manufacturing, E. Paul Degarmo, Wiley, 2011

Blow Molding Handbook : Technology,Performance,Markets,Economics. The Complete Blow Molding Operation, Rosato, Rosato & DiMattia, Hanser, 2003

Injection Mold Design Engineering, David O'Kasmer, Hanser, 2016

Injection Mould Design, RWG Pye, Longman Scientific

Journal Resources


URL Resources


Other Resources

Plastic and rubber weekly journal

Newscientist journal

Polymer journal, Kunstoffe, Modern Plastics,