Understanding Injection Molding of Thermoplastics – the key to optimum plastic part design

28 & 29 August 2018

Scandic Sydhavnen
Sydhavns Pl. 15
2450 Kbh SV

Taught in English by Professor Vito Leo, the BIMS-SEMINARS sprl.
The seminar has been upgraded. Many people will find it useful to attend a second time.

The seminar focuses on the complex phenomena behind the Injection Molding process with a strong emphasis on the understanding of part’s problems (aspect, shrinkage, warpage, weld lines, burns, etc.) and their relationship with material properties (amorphous, semi-cystalline, filled, unfilled) and the process itself.


  • basic polymer thermal and rheological behaviour
  • effect of pressure on polymer properties
  • the flow process in Injection Molding
  • part geometry and flow pattern
  • compressibility, phase change and PVT data
  • what is crystallinity and how does it affect processing?
  • the packing phase: key to the dimensional quality of the part
  • effective part, mould and process design for proper cavity packing
  • understanding the shrinkage build-up
  • part warpage mechanisms: designing for minimum warpage, according to material properties and part shape
  • warpage: the special case of fibre filled materials.
  • the concept of residual stresses: the compromise with warpage
  • final conclusions and wrap-up – seminar evaluation by the participants

The seminar is not specifically about Injection Molding Simulation. However, the intention is to clearly help those among the participants who are “Flow Analysis users” to gain a thorough understanding of the concepts that form the basis of the existing code. Model assumptions and corresponding limitations will be highlighted and discussed.

The seminar is highly interactive with limited attendance, allowing for questions, group discussion and an analysis of the attendants’ problems. Parts or drawings are welcome for open discussion, when possible.

The first part of the seminar will quickly describe the process cycle for the purpose of setting up a common vocabulary.

For more detailed information on the course content, please contact Vito Leo directly at: 
Dr. Vito Leo, Sentier de BOMAL 8, 1315 INCOURT – BELGIUM, vito@bims-seminars.com,
Tel.: +32 478 449709. FAX : +32 2 6125066.


  • the course is highly interactive
  • attendance is limited, allowing for questions, group discussions and analysis of attendant problems
  • parts drawings are welcome for open discussion when possible
  • a thorough introduction to the aspects of the polymer injection molding process in only two days
  • the seminar provides an opportunity to expand your professional network
  • Dr. Vito Leo has more than 25 years of experience in Polymer Processing and is known as an excellent teacher


  • design engineers in charge of molded parts
  • mold making specialists
  • molders
  • flow analysts looking for analysis interpretation support
  • project leaders involved in developing molded parts
  • research engineers interested in injection molding
  • mechanical engineers interested in process induced weakness and strength
  • material engineers or designers wishing to improve their understanding of a given class of materials (i.e. glass fiber filled polymers).
  • students involved in the field
  • young, skilled professionals with little field experience
  • flow analysis developers
  • customer support engineers

The seminar may not fit the needs of beginners in the field.


Vito Leo is a physicist by training, and has been working for more than 30 years in the field of Polymer Processing. He is particularly active in the field of Injection Molding of Thermoplastics and the use of Finite Element Numerical Simulation of this process.

He works for the largest chemical company in Belgium and is currently involved in a number of research projects in the field of Rheology and Injection Molding. He is also in charge of the Flow Analysis group that uses available commercial software to support injection-molding customers.

His well known expertise has recently gained him a position as Professor at Université Libre de Bruxelles, where he is currently teaching an introductory course in Polymer Processing to students of the Engineering Faculty.

As a professional in the Plastic Industry for many years, I have met a very large number of people involved in this field: part designers, mold makers, molders, technicians on the shop floor, or academic people involved in fundamental research. I have always had the impression that everyone has a limited view of the problems, a good understanding in his particular field, but usually little knowledge of the process as a whole. Even worse, people usually do not understand each other because their job and training background are so different. Very few part designers or project managers know about the really peculiar behavior of molten polymers in a molding process. And no University Professor or Flow Analysis developer seems to know how a molding machine really works or how a mold is made.

During my professional life I have tried to bridge the gap between those different approaches, being involved in academic research, attending conferences or training sessions, publishing papers, using software, but also spending a lot of time on the shop floor, running the machine myself, and working days and sometime entire weeks in molding shops throughout the world optimizing the process.

Flow Analysis Codes (Moldflow®, Moldex® and the likes) are now established and respected tools, readily available on PC and with excellent user interface and very good modeling capabilities. But optimum use and proper interpretation of results still requires very skilled and experienced specialists. The users I come across are often young computer minded engineers, with limited knowledge of plastics and processing technology.

I also noticed that the recent boom in the Mobile Communications Business is generating extremely fast growth in leading companies, where very young professionals are now in charge of world-wide projects, involving complex plastic parts, special materials, and very demanding dimensional and mechanical requirements. These engineers would benefit from an appropriate training in Injection Molding and Polymer Physics.

Now that I have a good understanding of the molding process and the underlying physics, I want to try to share my knowledge with people in the industry.

The challenge I give myself is the following: I want to go deeply into the physics of the various thermoplastics processing behavior, thoroughly explain the mechanisms involved in this complex process from filling to final warpage, and yet present this seminar material with simple words and concepts, and minimum mathematics, so that the whole interested community, with or without high level university training, will benefit from these training sessions.

The seminar has been presented to more than 1,700 participants throughout Europe, including private sessions at Nokia in Finland and Denmark, Ericcson and Nolato in Sweden, Bang & Olufsen and Novo Nordisk, Widex, Oticon in Denmark, Plastic Omnium, Adidas Salomon Sports, Valeo Lighting Systems and Hager Electro in France.


28 August 2018: 10:00 to 18:00
29 August 2018: 08.30 to 15.30.

Scandic SydhavnenSydhavns Pl. 15, 2450 København SV, tlf.: +45 8833 3666.

DKK 10.900 + 25% VAT.
Includes sessions during the two days, course materials, luncheons, coffee breaks and dinner the first evening. The price does not include hotel accommodation.

Reduced fee when registering before 7 July 2018: DKK 10.500 + 25% VAT.
Members of ATV-SEMAPP get a reduction of DKK 800.

Click to fill in REGISTRATION FORM and send it. Registration is confirmed shortly after by e-mail (please check your spam-filter if you do not recieve a confirmation).

Please contact the secretariat in case of problems with your registration:
E-mail to: semapp@atv-semapp.dk,
or phone Charlotte Leser, +45 4525 4899 or Jytte Laursen, +45 4525 4898.

Rooms at Scandic Sydhavnen can be booked via this Booking form.

Min. 12, max. 25 participants.

Cancellations received before 26 July 2018 are fully refunded. No refund for cancellations received after 26 July 2018. Substitutions are accepted at any time.