Plastic Injection Moulding Simulation and Analysis
Designing plastic parts can be a tricky business, as it often involves a significant investment in tooling for production.
Without proper simulation and validation at the early stages, this process can result in setbacks and unexpected costs. That's where our expertise in Injection Moulding Simulation, also known as MoldFlow, comes in.
Our team has the knowledge and experience to simulate the moldflow, filling, and packing processes, enabling us to predict the flow of material during injection.
This allows us to optimize your design for manufacturing at an early stage, reducing the need for costly tool iterations and avoiding the time-consuming and launch delaying months of tooling development.
Our expertise extends to designing double and triple shot components, which can be particularly complex and challenging. By using these simulation tools, we can ensure that even the most complex tools will work.
By simulating the loads put into the mould tooling by the flowing plastic, we can accurately predict the stresses and deformations that the tooling will experience during production. Combining this data with static FEA (finite element analysis) simulations, we can identify potential failure points in the tooling and redesign the part or tooling accordingly. This approach allows us to avoid costly tooling failures and reduce the risk of production delays.
By using Injection Moulding Simulation, we can provide you with an accurate insight into how the part will be formed, giving you greater control over the production process and reducing the risk of project delays or cost overruns. So why not let us help you to design plastic parts that are both effective and cost-efficient? Contact us today to discuss your project needs.
Have you had delays caused by injection moulded plastic parts not being to specification? How much did that delay cost? Injection Moulding Simulation allow you to check the mould tools virtually. Any problems can be identified in the design phase and resolved much more quickly and at a lower cost than having to make changes to a physical tool.
Do you have problems with surface quality such as sink marks? Does that put off customers? Injection Moulding Simulation allows us to see where sink will occur and alter the design to reduce thick spots or increase the flow channels to keep the area of sink under pressure while it cools.
Do your parts take too long to mould? Could you speed up production? We can simulate different gate sizes and positions to make sure that the part fill easily and evenly. We can also optimise the position of the ejector pins so that the plastic freezes earlier and you can eject quicker. For mass manufactured parts, saving a couple of second can add a lot to your margin.
Could you use less material? Could you reduce costs and minimise waste? Optimising the design of the part with Injection Moulding Simulation allows less material to be used. Lower material use is more environmentally friendly and saves you money. It also uses less energy to process, less energy to cool, is quicker to mould and lighter to ship, again, a double win, saving both the environment and your margins.
Are your components the wrong shape? Does that affect product performance? As plastic parts cool, the material shrinks and the part changes shape. If this shrinkage is uneven, the geometry of the part can be pulled out of alignment, the tolerances are poor and your parts don't work. This can all be simulated and designed out with Injection Moulding Simulation.
Are your parts unexpectedly breaking? Do you have many repairs under warranty? Even if you have undertaken FEA to strength test your parts, the flow of polymer into the mould can massively affect material strength. Perhaps the flow freezes and then carries on, perhaps there are two flow fronts colliding head on, perhaps there is so much shear heating that the polymer chains are ripped apart, perhaps so much packing pressure is needed that there is residual stress? We can see all of this with Injection Moulding Simulation and design it out before it ever becomes a problem.
Are your family moulds balanced? Do your parts work together?When making parts with a family mould that has multiple different parts, the runner system needs to be balanced so that all of the components mould successfully. Injection Moulding Simulation can help to get these set up correctly before cutting any cavities and saving a lot of set up time.
If you have had these problems before, and don't want them again, or if you are having these problems now, help is a click away.
We worked with Raymont-Osman to develop a solution to a moulded part distortion problem that we were having with a new multi-impression two shot tool. They suggested a number of component design changes to resolve the issue and then set up FEA simulations to investigate each solution virtually. When we did implement the chosen solution in the real world, it solved the problem straight away. It was a pleasure to work with them and I’m happy to recommend their services.
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