Part and process analysis with Moldflow

The first step towards achieving high component quality and stable process control.
After the first inspection of the CAD data for plastic-compatible design and constructive conspicuities, the injection concept is determined. The objectives of each simulation are to guarantee process reliability, to determine and optimize economic parameters, and to adhere to dimensions and tolerances.
  • 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

Determination of shrinkage, warpage, flatness and roundness as well as buckling potential for compliance with tolerances.

Evaluation with regard to optics and strength

After ensuring manufacturability, analyses of optical and mechanical properties are carried out.
A component of every simulation evaluation is the examination of the results with regard to optical defects and process-induced influences on the component strength. For example, in the case of 2 or multiple component parts, effects such as material adhesion, ink transfer or phenomena such as insert displacement in hybrid components are investigated.
  • 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

Identification of possible sink marks and streaks, void potential and thermal as well as mechanical melt loads to ensure quality requirements.

Material comparisons and optimization calculation runs

The simulation offers the possibility to investigate the influence of different materials on the quality of the component.
In optimization calculation runs, design, injection position and process control are suitably varied and cross-checked, if possible for the customer. The use of reference materials in the Moldflow simulation is always used if a material is not included in the database or if comparative calculations are to be carried out to determine the optimum 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 simulation results and thus their resilience for the product development process.

Concept studies and process comparisons

The evaluation of different process methods shows further optimization and saving potentials.
The goal of process comparing 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 Moldflow calculations!