This presentation, delivered by Torsten Kruse of Kruse Training, provides a structured, practical introduction to the core principles needed to achieve robust, predictable, and scalable injection molding processes. It integrates three foundational disciplines—Design for Manufacturability (DFM), Design of Experiments (DOE), and systematic cause-and-effect analysis—to establish a disciplined framework for process understanding and control.
The presentation begins by addressing Design for Manufacturability, demonstrating how early part and mold design decisions directly influence process stability, part quality, cycle time, and overall cost. Through practical, experience-based DFM guidelines, it illustrates how common risks can be identified and mitigated early in development, when design flexibility is highest, and changes are least expensive. Emphasis is placed on designing parts and molds that are inherently moldable, tolerant to variation, and aligned with realistic processing windows.
Building on this foundation, the presentation introduces Design of Experiments as a structured, data-driven methodology for understanding and optimizing injection molding processes. Rather than relying on trial-and-error or single-variable adjustments, DOE is presented as a systematic approach to identifying critical process variables, quantifying their individual and interactive effects, and efficiently determining optimal operating conditions. The discussion highlights how DOE accelerates learning, reduces experimental cost, and produces actionable insights that are statistically defensible and repeatable.
The presentation then connects DFM and DOE principles to real-world injection molding behavior, focusing on how process responses should be interpreted. It emphasizes the importance of distinguishing correlation from true causation, recognizing misleading signals, and linking observed outcomes to underlying physical mechanisms within the molding process. This perspective enables more accurate troubleshooting, stronger root cause analysis, and better decision-making under real-world production constraints.
Overall, the session equips engineers, technicians, and manufacturing professionals with a coherent framework for moving beyond reactive, experience-only approaches toward a disciplined, science-based methodology for process development, optimization, and control. The result is greater confidence in decision-making, improved process robustness, and more consistent, repeatable molding outcomes across products, tools, and production environments.
MD&M West 2026
Join us at MD&M West 2026, one of the leading events for medical device design and manufacturing, and connect with the Modlex3D team in person. Visit us at Booth #4346 from February 3–5, 2026, where we will be available to discuss your organization’s training and workforce development requirements.
Whether you are exploring new capabilities, scaling advanced manufacturing processes, or seeking customized training solutions, our experts will be on hand to share insights and discuss how Modlex3D can support your goals. We look forward to meeting you in Anaheim and starting a productive conversation about your training needs. Learn more about the event at: https://www.mdmwest.com
Plastics Technology Expo (PTXPO)
The Plastics Technology Expo (PTXPO) is one of North America’s premier trade shows for plastics processing professionals. The event brings together manufacturers, equipment suppliers, material providers, and technical experts to showcase the latest innovations, technologies, and best practices shaping the plastics industry. PTXPO serves as a key forum for education, networking, and hands-on exploration of advanced manufacturing solutions across injection molding, extrusion, automation, and related disciplines.
Attendees are invited to visit Booth #827 at PTXPO 2026 to learn more about Kruse Training, Inc., eLearning and Molding Expert, LLC, and their cutting-edge virtual reality (VR) mold training solutions. These immersive training platforms are designed to enhance workforce development, improve process understanding, and accelerate skill acquisition for plastics professionals at all experience levels. To learn more about the event, including registration and exhibitor details, visit www.plasticstechnologyexpo.com.
# # #
About Kruse Training & Molding Expert, LLC
Kruse Training is a comprehensive, subscription-based online knowledge and training platform developed for professionals involved in plastic product development and manufacturing. It is designed explicitly for part designers, mold designers, and senior process engineers who require both foundational understanding and advanced, practical expertise. The platform is future-oriented, addressing current industry challenges while preparing users for evolving technologies and best practices.
The Kruse Training curriculum is structured to present information in a clear, logical progression, ensuring that complex concepts are introduced, reinforced, and mastered systematically. Its proprietary focused-learning methodology integrates animations, simulations, instructional videos, quizzes, and multimedia presentations. This blended approach accelerates skill development, deepens technical understanding, and builds professional confidence by connecting theory directly to real-world application.
Kruse Training and Molding Expert, LLC shares a common mission: to help organizations develop highly effective, cross-trained teams capable of successfully designing and molding plastic components. When knowledge flows seamlessly from the part designer to the mold designer to the process engineer, and then loops back for continuous improvement, an actual Circle of Knowledge is created. This collaborative, systems-based approach reduces errors, shortens development cycles, improves part quality, and drives overall manufacturing efficiency.
Kruse Training provides the educational foundation that enables this collaboration, while Molding Expert, LLC delivers specialized expertise and a VR APP to support complex molding challenges. Together, they empower professionals and organizations to achieve consistent, high-performance results across the entire plastic product lifecycle.
For more information about Kruse Training, visit www.krusetraining.com.
For more information about Molding Expert, LLC, visit www.molding-expert.com.
