Full simulation of the injection molding process
Full simulation of the injection molding process for thermoplastics and thermosets, with or without fiber reinforcement. We analyze filling, packing, cooling, and post-ejection part behavior. Common defects like weld lines, short shots, air traps, or shrinkage are predicted and minimized, while injection and cooling system efficiency is optimized. We support standard and advanced molding techniques (multi-component, sequential, MuCell, gas/water assisted, etc.). Simulation results can be transferred to FEA solvers for structural behavior assessment after molding.
Plastic Injection for Automotive Dashboard
Predict and eliminate potential defects, such as warping, sink marks, and air traps, ensuring the production of high-quality components. This predictive capability also aids in the optimization of material usage, reducing waste and promoting sustainability.
Solver and material properties: Moldex3D
Simulate the complete injection process: Fill/Pack/Cool/Warp
Evaluate melt flow behavior into the mold cavity and predict potential molding problems upfront.
Assisting our customers in boosting troubleshooting capabilities and adding higher value to the plastic design-to-manufacturing process.
Validate design changes to reach the optimal plastic design and more efficient process conditions.
Plastic Injection – Melt Front and Weld Line Analysis
Understand the melt front progression during the injection molding process.Identify and mitigate key filling-related defects such as weld lines, air traps, short shots, and hesitation.Improve part quality and reduce cosmetic or structural failures caused by poor material flow behavior.
Solver and material properties: Moldex3D
Melt Front Tracking: Simulates how the molten material fills the mold cavity over time, revealing zones with slower flow or hesitation.
Weld Line Prediction: Determines the exact location, temperature, and formation angle of weld lines, which is critical for assessing the mechanical strength and surface appearance of the final part.
Defect Identification: Pinpoints:
Air Traps – regions where air may remain trapped, causing voids.Short Shots – incomplete filling due to flow imbalances.
Flow Hesitation – inconsistencies caused by geometry or thickness differences.
Avoid costly mold rework and late-stage quality issues.
Enable informed design iterations early in the development process.
Support decisions related to gate placement and part geometry for optimal flow behavior.
Ensure production-ready parts with minimized surface and structural defects.
Fluid-Structure Interaction for Core Shift prediction
Identify core displacement risks during injection molding due to unbalanced flow or high injection pressure.
Ensure dimensional accuracy of critical features influenced by core stability.
Support design adjustments to prevent variations in wall thickness or deformation-related defects.
Solver and material properties: Moldex3D
Core Shift Analysis uses fluid-structure interaction (FSI) to couple molten material flow with core deformation.
Key influencing factors evaluated include: Non-uniform melt flow, Injection pressure peaks, Part geometry complexity, Mold design constraints, Material rheology and viscosity
Simulation results predict: Core displacement magnitude and direction, Areas most affected by flow-induced stress, Wall thickness variation risks
Optimize part and mold design to reduce core movement
Adjust process settings before mold trials
Improve part quality and dimensional repeatability
Minimize rework, tooling adjustments, and production delays
Trunk side bracket design
Consolidate 2-piece welded assembly into a single, optimized part. Eliminate ultrasonic welding & reduce molds for simpler, faster manufacturing. Apply DFM for injection molding, targeting reduced mold complexity.
Redesigned 2-piece welded bracket into a single, integrated molded component.
Integrated Features: Combined functionalities of original parts into unified geometry.
Optimized for Single-Tool Molding: Designed for single mold ejection, minimizing complex actions (sliders/lifters) through careful consideration of draw, parting lines, & features.
Mass Reduction: Implemented design strategies for lower mass without compromising structural integrity.
Maintained Functional Interfaces: Ensured critical fixing points & interfaces were maintained/improved for stiffness & assembly.
Final CAD validated with DFM analysis & manufacturing partners.
Drastically reduced manufacturing complexity (single part vs. 2 + weld).
Decreased production cycle time (eliminated welding).
Lower tooling investment & maintenance (one mold vs. two + fixtures).
Simplified logistics & inventory (single part number).Improved part consistency & quality (no weld variation).
Reduced overall component mass through optimization.
Minimized mold actions (sliders/lifters), simplifying the mold & improving reliability.
