Mold Flow

Simulation of the injection process (Mold Flow)

Simulations of the injection molding process support the work of designers, tool builders and technologists. This is an important stage of digital prototyping that streamlines the implementation of the newly designed product into production. Thanks to simulation, implementation is able to be done quickly and efficiently, avoiding the tedious process of trial and error.
The full simulation of the injection molding process is a combination of the following stages: mold filling, post-packaging, cooling and shrinkage. The tools used make it possible to simulate all these stages. Simulations support the design and optimization of injection molds. Additionally, they allow us to predict potential inconsistencies in the geometry of the molded part already during the stage of mold design.

What does simulation of the injection process provide us with?

  • Minimize the complexity of the injection mold;
  • Reduction of process costs;
  • Optimization of injection points;
  • Evaluate the detail for deformation;
  • Optimization of the infusion system;
  • Location of areas of material weakness (weld line);
  • Ability to check multiple materials for properties (e.g., shrinkage);
  • Distribution of fiber orientation (fiber-reinforced plastics);
  • Optimization of the injection process cycle (reduction of injection, clamping, cooling and mold release times);

What do we simulate?

  • Mold fill
  • Packing
  • Cooling
  • Post-trial deformations (Warp)
  • Overmold
  • Two-component injection molding;
  • Injection with gas

In what areas is Mold Flow simulation needed?

Injection molds

Injection is the field that includes the design of optimized plastic feed and cooling systems. Injection mold optimization involves the evaluation and development of system geometry:

  • Plastic supply;
  • Mold cooling;
  • The ejector and release system of the molded part;
  • Mold opening/closing kinematics.

The evaluation of the entire design in terms of temperature distribution consists of a thermal analysis of the workpiece and an analysis of the cooling system. It is important to perform a full injection simulation based on the designed geometry of the cooling system to fully determine the mold temperature on the molding surface.

Product geometry

The geometry of the product is the field that focuses on the manufactured part. The main task of this area is to assist the manufacturing process in obtaining a product that conforms to design requirements.

The optimization of the product geometry is related to the selection of the injection point.  This ensures the forming cavity is filled evenly and avoids defects associated with temperature distribution. It also verifies the wall thickness of the workpiece and minimizes the risk of air traps or joint lines.

The final step in the “moldflow” simulation is a process in which injection speed, timing and clamping pressure are optimized. This results in minimized deformation and a reduced cycle time.

Other competencies

Aluminum die casting
Surface refinement
Functional tests