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Injection molding simulation - Moldflow – additional cost or key to flawless manufacturing?

Updated: Aug 18, 2023

In Matio we work closely with both talented toolmakers and creative product designers, who are each accountable for their individual sections.

A strong and practical tool, simulation of injection molding must be applied correctly. Conducting the Moldflow during the inquiry phase to conduct a feasibility analysis and evaluate the needs is crucial. Because toolmakers are frequently preoccupied with both scheduled and unforeseen activity, offers may be made in a hurry without enough time for feasibility studies.

It is recommended that part designers participate in injection molding assessments early in the design process. It is crucial to foresee any problems that can occur throughout the molding process, such as estimation of warpage and other pertinent elements, in order to determine the initial viability of creating a part.

Outcome from Injection molding simulation - part warpage deformation
Injection Molding Simulation - Moldflow -Warpage

Your results can only be as accurate as your input parameters

For successful and realistic Moldflow analysis results, a comprehensive approach is essential.

Making a Design for Manufacturing (DFM) report is vital and require significant investment in time and effort. Delve into the details of gate and runner design, cooling system, and parting lines, ensuring they are thoroughly understood. By gathering and analysing this data, the Moldflow analysis can yield optimized and efficient manufacturing processes, leading to better outcomes for your project.

Always perform a Cooling Analysis before predicting part warpage

Once you aim for a precise warping calculation, your results become highly dependent on realistic parameter input. On the other hand, if you focus on a simple fill calculation to predict melt front behavior, weld lines, and air traps, you can rely on default parameters and worry less about input accuracy, as they generally provide a realistic filling prediction.

When not performing a Cooling Analysis before you go and calculate Filling and Packing Stage, your assumption is that you have a perfect uniform mold wall temperature across all walls – which is the ideal cooling situation that happens rarely. It is more likely that you have a non-uniform temperature at the mold wall that lead to a unbalanced cooling. Such unbalanced cooling will result in an asymmetric tension-compression pattern across the part, causing a bending moment that will cause part warpage

Cooling channel Injection molding simulation presentation
Cooling channel Injection molding simulation

When we should do Injection Molding simulation – Moldflow and what are Moldflow benefits?

In the inquiry phase, conducting a Design for Manufacturing (DFM) report and Moldflow analysis is of utmost importance. These tasks are critical for ensuring the success of the manufacturing process.

The most important information which we want from Moldflow are:

- Flow information – short shots, weld lines, air traps

- Pack information – sink marks, gate freeze time

- Warpage information

multi cavity tool
Filling animation

Based on those information we can optimize DFM report, change gate location, runner system and more.

Once we obtain the latest revision, we can proceed with a virtual measurement of the deformed part. This enables us to assess whether the warpage is still inside requirements – given tolerances or not.

During this stage, adjustments can be made o the drawing's tolerances, modifications can be implemented on the part, and elements can be added or removed as needed, ensuring that the final product meets the requirement.

When we compile an offer along with a comprehensive report that combines all this information, we effectively reduce potential risks and minimize the likelihood of failures in the future. Additionally, having access to this wealth of information enables us to more accurately assess all the costs and prepare a more detailed offer.

What are the most common failures which we faced in tool manufacturing and part production?

- Visible sink marks on the part

- Draft angles noT OK

- Not OK part surface structure

- Warpage – dimensionally NOK part

- Burrs - flashes on part critical areas

Before tool construction starts

The DFM report has to be updated, and a new Moldflow analysis is equally vital. This assists in confirming that the part or material have not changed in a way that could have an impact on the outcomes. This guarantees that any foreseeable modifications to the part, the material, or other elements are taken into account.

With the final tool design and accurate input data available, performing the Moldflow analysis will produce highly accurate findings, revealing insightful information and lowering manufacturing process uncertainties.

Where can we help you

Whether you are a tool producer, tool manufacturer, or part designer, we can assist you.

You can send us information via the email address below, and we will make all necessary preparations.


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