Injection Molding Simulation Services with Moldflow

Make use of injection molding simulation services by the Plastics Engineering Group and achieve high component quality and stable process control.
Injection Molding Simulation is initially employed following the initial evaluation of the CAD data for plastic-compatible design and structural anomalies. Subsequently, Injection Molding Simulation is utilized to establish a gating concept. The objectives of each simulation encompass ensuring process reliability, identifying and optimizing economic parameters, as well as adhering to dimensions and tolerances. Our simulation services for the optimization of injection molded components may include:
  • Definition of injection positions, number of nozzles and switching sequences for cascaded filled components
  • Verification of fillability, balanced filling and determination of the process window
  • Determination and optimization of cycle time, pressure and clamp force requirements
  • Calculation and optimization of shrinkage, warpage, flatness, roundness and buckling potential, if necessary
Contact person: Sven Theissen

Evaluate and optimize shrinkage, warpage, roundness, and flatness to meet tolerances using Injection Molding Simulation by the Plastics Engineering Group.

Use injection molding simulation to evaluate with regard to optics and strength

After ensuring manufacturability, simulation analyses of optical and mechanical properties are carried out.
An integral part of our Injection Molding Simulation services is the analysis of results concerning optical defects and process-induced influences on component strength. For instance, in the case of two-component or multi-component parts, effects such as material adhesion, color bleed, or phenomena like insert or core shifting in hybrid components are examined.
  • Sink marks, streaks, void potential
  • Thermal and mechanical melt loading
  • Multi-component injection molding and In-mold decoration
  • Core shift and determination of the ideal preheating temperature for hybrid components
Contact person: Sven Theissen

With Injection Molding Simulation services, detect potential gate locations and flow marks, void potential, and thermal as well as mechanical melt stresses to ensure quality requirements are met.

Material comparisons and optimization calculation runs

Injection Molding Simulation services provide the opportunity to investigate the influence of different materials on the quality of the component.
During optimization iterations in Injection Molding Simulation services, if feasible for the customer, design, gate position, and process control are varied and cross-checked. The use of reference materials in Moldflow Injection Molding Simulation is employed whenever a material is not included in the database or when comparative calculations are needed to determine the optimal material for the customer-specific application.
  • Variation of design, injection position and process control
  • Comparison of optimization simulations to achieve optimal quality criteria
  • Comparative simulations with 2 or more materials
  • Procurement of material data from material manufacturers or use of comparable materials from the Moldflow database
Contact person: Sven Theissen

The quality of material data significantly influences the quality of Injection Molding Simulation results and thus their resilience for the product development process.

Concept studies and process comparisons with Injection Molding Simulation

The evaluation of different process methods shows further optimization and saving potentials.
The goal of process comparing Injection Molding Simulations is the identification of process-determining boundary conditions to achieve an optimal part quality with minimum use of resources. This applies to aspects such as material usage and weight minimization, as well as process methods and thermal influences on the component appearance due to special cooling technologies.
  • Speed controlled valve gate nozzles
  • Variothermal process control
  • Conventional vs. conformal cooling
  • Foam vs. compact injection molding
  • Injection stamping vs. injection molding
  • Gas injection molding and sandwich injection molding
Contact person: Sven Theissen

The best possible exploitation of savings potentials while simultaneously increasing component quality gives you a head start on the market. Increase your success with Injection Molding Simulations by the Plastics Engineering Group!

What is injection molding simulation?

Injection molding simulation with Moldflow supports the development process of components and helps optimize component geometry, clamping forces, pressures, and warpage.

Why is injection molding simulation used?

The costs for tools accumulate due to iterative changes, often doubling or tripling the originally estimated costs. In extreme cases, tools may need to be completely remanufactured due to excessive warpage. This can be prevented through simulation.

Why is Autodesk Moldflow used for simulation?

At PEG, we have been using Moldflow for 30 years because the software is user-friendly, many companies require it as a standard, and the results are, when elaborated with experience, reliable.

When is the ideal time to use simulation?

In general, the principle is: the earlier you start, the lower the costs. The biggest errors can be avoided during component design. The simulation strategy for our customers is presented on this page.