Mould Simulation Analysis
Have you previously had issues with problematic mouldings when this could have been captured before manufacture?
We’ve recently invested in a software package which enables component design to be validated with a Mould Simulation Analysis. The software allows us to gain product insights, visualise flow & thermal properties and optimise processes before physical parts are moulded.
The design process for injection moulded prototype components can be lengthy with many changes and iterations to ensure the final product is perfect. Using our new software we endeavour to catch design faults that could potentially cause setbacks during tool trial. This not only helps to improve quality but it also helps to reduce development costs and manufacturing times by eliminating potential issues by using the simulation to analyse the CAD model before manufacture begins.
We can simulate the filling patterns of injection moulding to help predict potential manufacturing problems such as weld lines, air traps, short shots, sink marks etc. We can also verify gate contribution for flow balance and create a melt delivery system including sprues, runners, and gates.
The pack feature incorporates the material compressibility (PVT changes) to fully simulate the density variation and melt flow behaviours during the packing process. It helps us to determine gate freeze time, efficient packing time and pressure, and warpage prediction to minimize high volumetric shrinkage.
This feature improves cooling system productivity and efficiency to optimise mould and cooling circuit designs and to reduce cycle times, especially with complex part design.
Warp provides a reliable analysis capability to simulate the key issues of shrinkage and warpage behaviour, further controlling the blemishes of moulded products. For fibre-filled material, Warp incorporates fibre composite theories and the fibre orientation results from Fibre to predict its anisotropic shrinkage and warpage.
Multiple Component Moulding (MCM)
MCM helps us to evaluate insert moulding and over moulding. It helps to accurately observe interaction behaviours and minimise part warpage. Moreover, this module helps to predict the warpage due to property mismatch of different materials, prolonged cooling time and unsymmetrical shrinkage in over-moulding processes.