Lesson 1Die and calibration tooling: die types for pipes and profiles, mandrels, vacuum sizing, land length and swell controlDiscusses die and calibration tooling for pipes, profiles, and sheets. Explains flow distribution, mandrels, land length, swell control, and vacuum sizing, relating tooling design to dimensional accuracy and surface finish.
Pipe, profile, and sheet die typesFlow distribution and manifoldsMandrels, pins, and spider supportsDie land length and swell controlVacuum sizing plates and sleevesLesson 2Haul-off and downstream: belt pullers, caterpillar haul-off, speed synchronisation with extruderExamines haul-off and downstream pulling equipment, including belt and caterpillar units. Covers traction control, nip pressure, and speed synchronisation with the extruder to ensure product dimensions and surface quality.
Belt pullers vs caterpillar haul-offSpeed synchronization with extruderNip pressure and slip preventionEffect on wall thickness and ovalityIntegration with downstream cuttersLesson 3Cooling and sizing equipment: water cooling baths, spray rings, cooling tanks, calibrators, vacuum sizing systemsReviews cooling and sizing equipment post-die, such as water baths, spray cooling, and vacuum calibrators. Discusses heat removal rates, dimensional control, internal stresses, and cooling profiles' effect on warpage.
Water baths and spray ring designCooling tanks and residence timeCalibrators for profiles and sheetsVacuum sizing for pipes and profilesCooling rate, stress, and warpageLesson 4Screw geometry and selection: screw diameter ranges, L/D ratio, flights, compression and metering zonesExplains screw geometry elements and their role in melting, mixing, and pressure generation. Includes diameter, L/D ratio, flight design, compression and metering zones, and tips for selecting screws for various polymers and outputs.
Screw diameter and L/D ratio effectsFeed, transition, and metering zonesFlight depth, pitch, and channel volumeBarrier and mixing section optionsScrew selection for materials and outputLesson 5Instrumentation and gauges: melt pressure transducers, die pressure, barrel temperature sensors, flow meters, infrared profile measurementCovers essential extrusion instrumentation like melt and die pressure, barrel temperature sensing, and flow measurement. Stresses sensor placement, calibration, data interpretation, and integration with alarms and control systems.
Melt and die pressure transducersBarrel temperature sensors and placementFlow meters and mass flow monitoringInfrared profile and surface temperatureCalibration, drift, and signal filteringLesson 6Hopper and material handling: dryers, feeders, gravimetric vs volumetric dosing, contamination controlFocuses on hopper design and material handling, covering drying, conveying, and dosing. Compares gravimetric and volumetric systems, stresses moisture and contamination control, and shares practices to prevent bridging and segregation.
Hopper design, liners, and bridgingDryers and moisture specification limitsPneumatic and mechanical conveyingGravimetric vs volumetric dosingContamination and metal detectionLesson 7Additive and colour feeding systems: side feeders, loss-in-weight feeders, masterbatch feeders, pigment dispersion basicsExplores feeding systems for additives and colourants, comparing volumetric and gravimetric designs. Covers side feeding to twin-screws, masterbatch dosing, pigment dispersion quality, and methods to avoid segregation and colour streaks.
Volumetric vs loss-in-weight feedersSide feeders for fillers and regrindMasterbatch feeders and color dosingPigment dispersion and streak controlRefill systems and material segregationLesson 8Types of extruders: single-screw vs twin-screw — principles, advantages, typical applicationsCompares single-screw and twin-screw extruders, covering operating principles, melting and mixing behaviour, and design impacts on throughput, energy use, and suitability for compounding, recycling, and profile or film extrusion.
Single-screw operating principle and meltingTwin-screw co-rotating vs counter-rotatingDistributive and dispersive mixing behaviorTypical applications and material suitabilityEnergy efficiency and throughput comparisonLesson 9Cutting and finishing: flying saws, cold cutters, trimming units for profilesDescribes cutting and finishing units for extruded products, including flying saws and cold cutters. Explains line speed synchronisation, burr and dust control, dimensional accuracy, and profile trimming to specifications.
Flying saws for continuous profilesCold cutters for pipes and tubesCut length control and tolerancesBurr, dust, and chip managementEnd finishing and chamfer optionsLesson 10Extruder main components: barrel zones, feed throat, screw, gearbox, heaters, thermocouples, melt pumpIdentifies key mechanical and thermal components of an extruder. Explains barrel zones, feed throat, screw, gearbox, heaters, thermocouples, and melt pump, and their design and maintenance effects on stability and output.
Barrel zones and cooling circuitsFeed throat design and ventingGearbox, motor, and torque limitsHeaters, thermocouples, and controlMelt pump function and pressure build
