Press release submitted on behalf of AIM.
The American Injection Molding (AIM) Institute announces the addition of David Zaffino as Mold Maintenance Instructor within its Mold Maintenance Center of Excellence (MMCE). Zaffino will guide students through the Institute’s mold maintenance education and training programs, taking over instruction as long-time instructor Glenn Keith prepares for retirement.
Zaffino brings 45 years of hands-on industry experience to the classroom. His career began as early as high school and continued throughout college, working for 4 years as a production shop machinist to put himself through Penn State, where he earned his Mechanical Engineering Technology degree. After a year in architectural detail drafting, he transitioned into plastics, spending 12 years in injection mold detail drafting and design.
Driven to follow projects from initial drawing through customer approval, Zaffino moved into tool shop support and spent 27 years in senior design, project coordination, tooling engineering, and tool room leadership roles. Working directly alongside toolmakers to oversee mold builds to completion built a foundation of trust, practical shop floor knowledge, and informal coaching that led him to classroom instruction. He further broadened his technical background by completing a degree in Plastics Engineering Technology at Penn State Behrend.
His approach to education and training was shaped by many key mentors throughout his career. For example, his father, a World War II veteran, father of six, machinist, and Zaffino’s first boss, taught him core mechanical principles alongside two foundational rules: strive to learn something new every day and treat everyone with respect. Later at Penn State, John Beaumont spent one-on-one time explaining the science behind injection molding, helping Zaffino challenge the status quo, rethink the approach to mold design, and connect practical shop-floor decisions to underlying technical principles.
By collaborating with toolmakers of all personalities across his career, Zaffino learned the value of straightforward communication and respecting each individual’s distinct needs. He draws on his experience to adapt his instruction to the varied abilities and backgrounds of his students.
Technicians in Zaffino’s courses learn to approach failed molds as investigators first. Before starting repairs, they gather data, measure components, trace root causes, and document findings. Back on the plant floor, these professionals step up to lead collaboration between process teams, mold setters, and operators, ending the cycle of rushed repairs and repeat breakdowns.
“I have received guidance and training from many people over 45 years, and I am dedicated to passing this knowledge along,” said Zaffino. “My role is to give students the space to navigate complex scenarios. The most rewarding moment is watching a student think through a systematic issue and resolve it independently.”
“Our mission has always been to help technicians become independent problem solvers rather than reactive mechanics. David understands how molds are designed, built, and run, and his practical background gives students the exact foundation they need to take ownership of troubleshooting on their own plant floors. I am glad to welcome him to the team,” said Glenn Keith, Mold Maintenance Instructor at the AIM Institute.
“We will certainly miss Glenn as he retires, but he certainly has earned his stripes in the industry and deserves some time to himself and his family. We wish him the best and thank him for all he has done not only for the AIM Institute but for his students in helping them build their talents and careers. We are fortunate to have Dave Zaffino stepping up to take over for Glenn. Dave is approaching this role with a strong passion for teaching, and we know he will do a wonderful job keeping up the quality of instruction our students have come to expect. The fact that he has lived in injection molding processing while working with moldmakers and techs will help him give our students a unique insight on bridging the gap between maintenance and production”, said David Hoffman, Director of the AIM Institute.
Zaffino will teach the full mold maintenance course lineup, including troubleshooting, hot runner repair, component welding, polishing, texture repair, and maintenance strategies.
Please join us in welcoming David Zaffino to the AIM Institute. We look forward to the knowledge and experience he will bring to our students in the Mold Maintenance program.
About The AIM Institute
The AIM Institute’s educational and training courses are rooted in research and are designed to help students solve problems using critical thinking by expanding their knowledge and skills. They are trusted worldwide to develop injection molding professionals through accredited education and training and are driven by the mission of advancing the injection molding industry.