Injection molding simulation

Filling analysis

Filling Image | Pressures | Flash | Sink Marks

The results of the filling analysis allow us to determine the most fundamental information characteristic of injection molding. In this phase of the injection molding simulation, the virtual filling of the mold cavity occurs, providing the opportunity to filter out numerous errors. We can obtain an accurate picture of what happens as the melt advances, whether flash fronts and air traps form, and if so, where they occur, which can cause quality defects in the product. Based on the results of the Moldflow analysis, timely decisions can be made to prevent flashes on visible or loaded surfaces. The most challenging issue with sink marks is determining whether they will cause noticeable surface defects in a given area or whether their extent will be negligible.

Packing analysis

Packing Time Determination | Clamping Force Calculation | Gate Freeze Determination

An adequately long and intense packing phase is essential for manufacturing a good product, as it compensates for the material shrinkage that occurs during cooling. If this compensation is not achieved, sink marks, warpage, and deformation occur in the piece. With Moldex3D simulations, the criteria for gate freeze can be established, thereby identifying areas where volumetric shrinkage undesirably increases during the process. With Moldex3D, the necessary clamping force for the product manufacturing can be precisely defined.

Cooling analysis

Cycle Time Reduction | Cooling Circuit Optimization

Accurate knowledge of the tool's temperature conditions is critically important for determining the cycle time and also for identifying places where special heat-conductive steel inserts (e.g., Ampco) must be used during tool production. A properly designed cooling system ensures low cycle times, reduces warpage, and extends tool life. With the Moldex3D cooling simulation, even before the tool design is completed, we get a real picture of the temperature differences within the tool and their effects from cycle to cycle. It is advised to optimize the tool insert layout and steel selection based on simulations run with precisely planned cooling circuits during the tool design phase.

Warpage analysis

Warpage | Product Shrinkage | Cavity Compensation

Undoubtedly, the most delicate area of the profession is determining the shrinkage and warpage of injection-molded plastic parts. Adherence to the tolerances of complex engineering plastic products can only be guaranteed by correct product design, appropriate tooling, and an optimized manufacturing process combined. It is critically important to perform a warpage analysis before signing the feasibility study, which helps evaluate the product tolerance fields and highlights potential warpages and deformations.