Molding Innovation Days 2014: Massachusetts, USA
Publish Date | 2014/02/20
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  • Event title: Molding Innovation Days 2014: Massachusetts, USA
  • Date: Mar 24, 2014-Mar 25, 2014
  • Location: Lowell, MA
  • Event type: Past Events

molding-innovation-day-2014-massachusetts-usa

Moldex3D, in collaboration with the UMASS Lowell, will be hosting a two-day event “Molding Innovation Days” for industry peers to explore the ins and outs of the latest molding technologies. Enjoy access to both theoretical and practical “Lean Manufacturing Solutions” shared by the industry-leading technology providers. The seminar is going to be held on Monday, March 24th followed by an optional hands-on workshop on Tuesday, March 25th at the UMass Lowell Inn & Conference Center. Participation is free. Join us for this informative seminar plus an interactive hands-on workshop where industry leaders come together to share their lean thinking and solutions!


 Featured Topics

blue-cube Flow Control Runner Systems blue-cube Conformal Cooling blue-cube Plastic Injection Molding Simulation Technology blue-cube MuCell®  blue-cube Hands-on Practice on CAE Simulation Software


Agenda

DAY 1: SEMINAR│Monday, March 24 2014

Time Topic Presenter
09:00 – 09:30 Registration/Breakfast
09:30 – 10:00 Welcome and Overview of UMass-Lowell Prof. Robert Malloy
Professor and Department Chair, Plastics Eng.
UMass-Lowell
10:00 – 10:30 Next Generation Flow Control Runner Systems Improve a Variety of Injection Molding Processes Mark Moss
Executive VP-Market & Product Strategy
Synventive Molding Solutions
10:30 – 10:50 Coffee Break
10:50 – 11:20 Conformal Cooling: Why Molding Lean Leads to Green Lou Young
Director of New Business Development
Linear Mold
11:20 – 11:50 Advanced Process Controls for Injection Molding Zachery Johnson
Applications Engineer
Priamus System Technologies, LLC
11:50 – 01:00 Lunch Break  
01:00 – 01:30 CAE Applications in Plastic Injection Molding Prof. Fang Lai
Department of Plastics Eng.
UMass-Lowell
01:30 – 02:00 Moldex3D Simulation Technology for Innovative Molding Processes Dr. Anthony Yang
President
Moldex3D North America
02:00 – 02:20 Coffee Break
02:20 – 02:50 MuCell® Injection Molding: Unique Process Solutions for Lightweight Parts Levi Kishbaugh
VP Engineering
Trexel, Inc.
02:50 – 03:20 Value Added High Temperature Polymer Challenges Rick Mahan
Sales & New Technology Manager
Hi-Tech Tool & Mold
03:20 – 03:50 Q & A, Raffle and Farewell

*Agenda is subject to change

DAY 2 : Half-Day Optional Training│Tuesday, March 25, 2014

Time Topic
09:00 – 09:30 Registration
09:30 – 09:50 Moldex3D Analysis Overview
09:50 – 10:20 Your first Moldex3D Analysis on your part*
10:20 – 10:40 Break
10:40 – 12:00 Result Interpretation
12:00 – 01:00 Lunch Break
01:00 – 04:30 More Moldex3D Hands-On practice and Result Discussion (Optional)

*Please bring a part in a supported format


Venue

UMass Lowell Inn & Conference Center
Website: www.acc-umlinnandconferencecenter.com | Address: 50 Warren Street, Lowell, MA 01852 | Phone: 978-934-6920 (Map & Directions)


Event Contact

Alyssa Studebaker │E: sales.us@moldex3d.com │T: 248-946-4570


Sponsor

ENESPESmall

Connecticut SPE

Event Gallery

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Special Prize

Beijing University of Chemical Technology

Improvement on the 2.5 Inch NPSM Screw Thread Requirement of a Plastic Bottle Cap


2015GITA_s09 Problem:
The goal of this project was to minimize the volumetric shrinkage of a plastic bottle cap in order to meet the 2.5 inch NPSM screw thread requirement without compromising the final product quality. With this goal in mind, an in-depth study on the mold cavity dimensional design was conducted in hopes of successfully controlling the precision of the screw thread within the acceptable tolerance.

Solution:
Two important processing parameters that influence the part shrinkage are packing pressure and packing time. In this study, Moldex3D was utilized to optimize the part/mold design and further identify the appropriate packing conditions to successfully adhere to the NPSM screw thread requirement.

Benefit:
BUCT was able to successfully control the precision of the screw within the acceptable tolerance. The part reject rate was significantly lowered from 90% to 5% which ultimately helped generate a greater business value for manufacturing companies, as well as, reducing material wastage.

Software used:
Moldex3D Advanced
- Fiber
- Flow
- Pack
- Warp

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Special Prize

National Yunlin University of Science and Technology

The Study of Product Warpage in Co-injection Molding


2015GITA_s08 Problem:
In co-injection molding, warpage is strongly associated with its core/skin material ratio. In order to improve product warpage, the team turned to the help of Moldex3D’s MCM solution to gain an in-depth understanding of co-injection molding. The effects of skin/core material ratio, processing parameters, and warpage behavior are investigated further in this study in order to improve product warpage.

Solution:
Moldex3D’s solution for multi-component molding (MCM) was utilized in this study. Simulation results helped identify the potential problematic areas and pinpoint the crucial factors influencing the product warpage in the early product development stage. The accurate simulation results were further validated by an actual mold-trial. Through Moldex3D simulation analyses and the actual mold-trial results, the team was able to clearly understand the phenomenon of the skin/ core ratio and further concluded that the product warpage could be improved by adjusting the amount of the injected core material, lowering the melt temperature, and reducing the flow rate of the first shot.

Benefit:
- Reduced warpage
- Optimized process parameters

Software used:
Moldex3D Advanced
- Flow
- Warp
- Co-injection
- MCM

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Special Prize

National Chiayi University

Applying Static Mixers in a Multi-cavity Design to Reduce Runner’s Corner Effect


2015GITA_s07 Problem:
In order to facilitate mass production and reduce overall costs, a multi-cavity system has been a prevalent mold design to improve production efficiency. However, a flow imbalance issue has been a commonly-found trouble experienced by many mold designers. Generally speaking, adding one more cavity, the product precision would decrease approximately by 4%.

Solution:
Moldex3D analysis was utilized to precisely simulate the injection molding process of a multi-cavity system. NCU was able to observe the cutting, rotating, and mixing effects of the plastic meltafter applying static mixers in the runner design, evaluate the static mixer’s performance, and test different static mixer designs. Thus, at the end, NCU could identify the best static mixer design to further solve the flow imbalance issue of a multi-cavity system.

Benefit:
- According to Moldex3D analysis results, the temperature distribution and flow balance could be improved effectively after the plastic melt passed through a static mixer.
- Moldex3D particle tracer was applied to better analyze the polymer particle filling behavior inside the cavity, making it easier to compare the pros and cons of using different static mixer designs and identify the best static mixer placement arrangement in order to achieve the most optimal design.

Software used:
Moldex3D Advanced
Moldex3D eDesign

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Special Prize

National Taiwan University of Science and Technology

The Study of the Effect of Glass Fibers on Poly Lactic Acid (PLA) and Structural Integrity


2015GITA_s06 Problem:
Environmentally degradable polymers and plastics (EDPs) are a group of polymeric materials experiencing a rapid growth in number as well as in their applications and quantities used. Polylactic Acid (PLA) is a biodegradable thermoplastic derived from renewable resources, such as corn starch, tapioca roots, chips or starch, or sugarcane. PLA can be used in manufacturing products like food containers as well as medical bone screws and plates. This goal of this study is to get a more comprehensive understanding of how glass fibers including both long and short fibers influence the mechanical properties of PLA products and pinpoint the important injection molding processing parameters in order to serve a valuable reference for future PLA product development.

Solution:
Moldex3D simulation technology was utilized to study the two different molding scenario of using PLA material with and without adding any fibers. Next, a detailed simulation analysis was done to further differentiate the effects of using short and long fibers in injection molding process with PLA material. Then, Moldex3D FEA interface was used to transfer essential injection molding simulation data to ANSYS software for a further analysis on product structural integrity.

Benefit:
Through Moldex3D simulation analyses, NTUST was able to understand that the fiber orientation result is highly associated with the filling behavior and they could further identify the different fiber orientation results in the freeze layer, the shear layer and the core layer. Then, with a close integration of Moldex3D and structural analysis software-ANSYS, a more precise analysis on product structural integrity could be achieved. Thus, with the accurate simulation results, NTUST was able to conclude that long fibers possess better functionality over short fibers due to its superior performances in fiber orientation, tensile strength, impact strength, and warpage.

Software used:
Moldex3D Advanced
- Stress
- Fiber
- FEA Interface

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Special Prize

National Kaohsiung University of Applied Sciences

The Cause of Sink Marks and the Dynamic Measurement of Thick Lens for Automotive


2015GITA_s05 Problem:
Thick lens molding has become a future trend for automotive lighting applications. However, undesirable product defect- sink mark is one of the biggest technological challenges in the production of thick-wall parts. It is due to the residual heat within the center of the thick lens parts after the parts are ejected from the mold cavity; thus, it gives rise to a possible re-softening of the already solidified part surface which ultimately leads to unwanted sink marks.

Solution:
Moldex3D was utilized in this study to validate the residual heat phenomenon and the occurrence of sink marks. Thus, the purpose of this study is to find out the most appropriate processing parameters for a sufficient cooling to avoid sink marks which ultimately leads to better production efficiency.

Benefit:
By utilizing Moldex3D analysis, NKUAS was able to successfully predict and avoid potential problems that might lead to poor product quality; thus the production efficiency could be greatly enhanced.

Software used:
Moldex3D eDesign
- Optics

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Special Prize

National Kaohsiung University of Applied Sciences

Applying MCM Process in Thick Lens Design


2015GITA_s04 Problem:
Thick wall processing issues which can include sink marks, voids/bubbles, jetting marks and longer cooling times. The visual defects are caused by a bigger mold cavity space and part shrinkage induced by the solidified plastic melt; longer cooling times are generally a result of the poor thermal conductivity caused by the uneasy heat dissipation within the thick wall sections of the part.

Solution:
This study features an optical lens with a heavier thickness design of 12mm. The concept of MCM sandwich molding was implemented in the form of B-A-B molding sequence layer design. Moldex3D’s MCM analyses were utilized to study the appropriate thickness design for A and B layers in order to achieve the shortest cooling time.

Benefit:
- Cooling time were drastically shortened by 50-60% after changing the thickness of A layer to twice as thick of B layer.

Software used:
Moldex3D Advanced
- Optics
- MCM

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Third Prize

The Ohio State University

Microinjection Molded Miniature Freeform Alvarez Lenses


2015GITA_s03 Problem:
Microinjection molding is a mass production method to fabricate affordable optical components. However, the intense nature of this process often results in part deformation and uneven refractive index distribution. These two factors limit the precision of replicated optics.

Solution:
In order to understand the influences of injection molding to freeform optical devices, in this study, Moldex3D’s finite element method (FEM) was employed to investigate the miniature microinjection molded Alvarez lenses. In addition, Moldex3D was also used to explain the differences between the nominal and experimentally measured wavefront patterns of the microinjection molded Alvarez lenses.

Benefit:
- Utilized the information of part deformation and uneven refractive index to calculate the optical aberrations of the injection molded Alvarez lens
- Significantly increase production yields by 99%
- Compensated optical aberration by modifying the original surface to obtain ideal MTF results

Software used:
Moldex3D Advanced
- Optics

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Second Prize

National Kaohsiung University of Applied Sciences

The Study of Volumetric Shrinkage using Zirconia Ceramic for Artificial Dental Roots with Two-shot Sequential Molding Application


2015GITA_s02 Problem:
As opposed to using conventional molding, one of the concerns of applying MCM process in manufacturing is the interchangeable mechanism between the different materials. When two or more materials are injected in the mold to form a part, the intricate interface between the different materials and the complexity of the geometric design are strongly related to the final product quality. Molding problems like an imbalanced flow behavior might lead to undesirable defects such as stress concentration or residual stress which ultimately influences the interface bonding strength and the overall product life span. Therefore, potential molding problems for example, product shrinkage and deformation might occur due to the different material properties and geometric part designs, and the quality of the finished products might be compromised.

Solution:
Utilize Moldex3D simulation to analyze PIM and MCM processes in order to further determine the proper product structure design and examine potential molding problems, such as short shots, air traps, excessive pressure, uneven cooling, or warpage. In order to improve the product quality, NKUAS resorted to Moldex3D’s solutions to simulate PIM and MCM processes to further observe the phase separation phenomenon of the powder and the adhesive, and visualize insert molding in hopes of determining the most optimized design. The accurate prediction on the powder density and distribution prevented the occurrence of stress concentration and residual stress and the ultimate goal of reducing volumetric shrinkage and product warpage could be achieved.

Benefit:
- Improved powder concentration distribution
- Solved warpage problem
- Enhanced the part quality by 71.15%

Software used:
Moldex3D eDesign
- Powder Injection Molding
- MCM

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First Prize

Chung Yuan Christian University

A Study of the Influences of Processing Parameters and Glass Fiber Material on Part Roundness using Moldex3D


2015GITA_s01 Problem:
One of the biggest challenges encountered in the camera lens hood production is “warpage.” Warpage is generally caused by the uneven shrinkage of the part. It is believed that if the volumetric shrinkage is consistent throughout the whole part, the roundness value of the part will only become smaller in size instead of resulting in product deformation or warpage. However, controlling a consistent shrinkage volume throughout the whole part is a complex task and not easy to achieve; many factors such as fiber orientation, mold cooling, processing parameters, etc. affect the success of the shrinkage control.

Solution:
With Moldex3D analyses, Chun Yuan University was able to attain the most optimal processing parameters, as well as, gain a comprehensive understanding of how glass fiber material influences the precision roundness of the part. The accurate simulation results were validated by an actual mold trial and the ultimate goal of improving the precision roundness of the part within the tolerable range could be further achieved.

Benefit:
- Achieved a balanced fill pattern
- Optimized the part roundness by 35%

Software used:
Moldex3D eDesign
- Fiber

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Special Prize

Linear Mold & Engineering

Improvement of Injection Molding Cycle Process


2015GITA_b09 Problem:
With injection molding many tools have longer than acceptable run times due to the limitations of conventional cooling methods. In addition to the longer run times, warpage is a serious factor when producing parts and often times result in excessive scrap in any attempts to reduce cycle time. The aim of this project was to help a customer to improve unacceptable lengthy run times on a tool.

Solution:
Linear Mold & Engineering utilized Moldex3D software to analyze a conventional cooling approach to a tool in question, showing where the areas of concern were that would demand long run times and produce extensive warpage of the part. Taking the results Moldex3D produced, Linear Mold then developed a solution in the form of conformally cooled components to replace or modify existing components in the tool to streamline the injection process. With a small amount of cycle process modification over the course of a day, the customer achieved the time savings Linear Mold predicted within a 3% margin of error.

Benefit:
- Reduced cycle times by 15-50 %
- Solved warpage problem
- Developed a competitive advantage in the market

Software used:
Moldex3D Advanced
- Flow
- Pack
- Cool
- Warp
- Fiber
- Stress
- CADdoctor

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Special Prize

Calin Technology Co., Ltd.

Moldex3D Injection Molding Simulation Applications in Projector Lens


2015GITA_b08 Problem:
The weld line occurred on the surface of the project lens when the melt entered the thin section in the middle of the part. The finished part needed to achieve uniform residual stress in order to maintain excellent optical properties.

Solution:
Moldex3D was utilized to optimize process parameters and run virtual molding simulations. It helped Calin Technology to determine the best combination of process settings for molding the projector lens. Using the optimum process conditions along with compensation method technology, Calin Technology was able to compared the simulation results to experimental results and verified that the requirements had been met with the help of Moldex3D.

Benefit:
- Improved weld lines to meet surface quality
- Achieved uniform distribution of shear stress

Software used:
Moldex3D Advanced
Moldex3D eDesign
- Flow
- Pack
- Cool
- Warp

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Special Prize

KOPLA

Solving Warpage Problem through Injection Analysis and Structural Analysis


2015GITA_b07 Problem:
In this project, KOPLA was tasked with reducing the risk of assembly problems on a door module part. The door module part consisted of many mounting holes for assembly purpose. Therefore, the location of the mounting holes was very crucial and required thorough investigation.

Solution:
KOPLA utilized Moldex3D simulation solution to identify the optimum gate location that could lead to good flow pattern and low warpage displacement. After the best gate location was identified, KOPLA output the warpage simulation result to ANSYS using Moldex3D FEA interface to increase the accuracy of the structural analysis.

Benefit:
- Obtained more realistic structural analysis
- Reduced cycle time and improved product quality

Software used:
Moldex3D eDesign
- FEA Interface
- Flow
- Pack
- Cool
- Warp

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Special Prize

Metal Industries Research Development Centre

Analyzing the Optical Properties of a Double-sided Micro Lens Array in Laser Projectors


2015GITA_b06 Problem:
Micro lens arrays (MLA) are one of the key components of laser-illuminated projector systems. After injection, the lens usually will warp as it cools because of the large difference in temperature. In this study, the Metal Industries Research Development Centre (MIRDC) aimed to use Moldex3D Optics for molding condition optimization to reduce optical quality issues, e.g., shrinkage, cracks, and residual stresses etc., to ensure uniform brightness.

Solution:
To effectively reduce residual stresses and warpage, Moldex3D enabled MIRDC to determine the optimal processing conditions through the Design of Experiments analysis, varying mold temperature, injection velocity and packing pressure factors. The simulation results then were compared to experimental results to further investigate the fringe orders and optical paths. The results showed that higher velocity can help improve the fringe orders and optical paths, and increased packing pressure and time can help improve warpage.

Benefit:
- Improved warpage by 30%
- Reduced optical path difference from 3.483X10-4 mm to 1.460X10-4mm
- Cut down mold trials and save costs

Software used:
Moldex3D Advanced
- DOE
- Optics
- Flow
- Pack
- Cool
- Warp

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Special Prize

Synventive Molding Solutions

Using Moldex3D to Simulate Synventive’s activeGate™ Technologies


2015GITA_b05 Problem:
With large injection molded parts, it is common to use a multiple drop hot runner system. Also common with this type of part is to use sequential filling as to eliminate weld lines. However, when molders use sequentially valve gates, there is a possibility that some common defects will occur. These defects are pressure transition marks on unpainted parts, reflection marks after a paint drying process and hot spot marks opposite of a direct gated nozzle. These defects are a result of a change in pressures and the fact that polymer melt is compressible.

Solution:
In this project, two analyses were conducted. The first analysis was done with standard sequential valve gating and was designed to see if the simulation can help identify the problem areas. The second simulation was also sequenced, but opening strokes of the delayed pins were controlled. The purpose of the second analysis was to find out if the simulation can help validate the activeGate controls. With Moldex3D simulations, Synventive were able to identify molded parts that could potentially have defects, which would cost time and money, before the tool is ever machined. Additionally, the ability to simulate the advanced pin control allowed Synventive to alter the characteristics of the fill and possibly eliminated any defects found in the injection molded part.

Benefit:
- Enabled pin movement simulation to identify defects that can be eliminated by activeGate controls
- Early detection of common defects in injection molded parts
- Saves molders time and money by scrapping less parts

Software used:
Moldex3D Advanced
- Advanced Hot Runner

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Special Prize

Acer Inc.

Using Design of Experiment (DOE) Analysis to Solve Ink Washout and Residual Stress Issues in Thin-wall Injection Molded Ultrabook Base Cases


2015GITA_b04 Problem:
In-mold Roller (IMR) technology is widely used in manufacturing ultrabook cases, which can provide scratch-resistance and design flexibility advantages. However, in this case, the thin-wall injection molded base case of the ultrabook had ink wash-out and residual stress problems. Moreover, the base case needed to meet the product specification for a wall thickness of 0.8mm.

Solution:
Moldex3D Design of Experiment (DOE) analysis was implemented to determine the optimum gate type and processing conditions. ACER used the optimum processing conditions obtained from the DOE analysis to adjust gate and wall thickness designs to avoid ink washout and residual stresses.

Benefit:
- Minimized ink washout and residual stresses
- Optimized wall thickness by 48%
- Reduced product weight by 40%

Software used:
Moldex3D eDesign
DOE

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Third Prize

TYC Brother Industrial Co., Ltd.

Solving Air Traps in BMC (Bulk Molding Compound) Automotive Headlight Reflectors


2015GITA_b03 Problem:
BMC (Bulk Molding Compound) reflectors are one of the most important components of headlights. Molding BMC reflectors is quite challenging due to the high surface quality requirements; surface defects will cause problems in the aluminizing process. In this case, TYC needed to overcome the quality issue of air traps in the mold to meet the demands from the customer.

Solution:
TYC used Moldex3D Advanced for filling simulation analysis of the BMC reflector part. The analysis result accurately identified where the air traps would be in the original design. Moreover, Moldex3D helped TYC validate how changes to gate locations and wall thickness can affect air trapping before making physical changes in tools.

Benefit:
- Eliminated air traps
- Reduced costly physical prototypes

Software used:
Moldex3D Advanced
- Flow

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Second Prize

TomTom

Using Moldex3D to Reduce Warpage in a Cradle of Truck GPS Navigation Devises


2015GITA_b02 Problem:
The front cover of the truck GPS navigation cradle is made with nylon with 50% fiberglass. During the injection molding process, the warpage occurred and led to a gap between the front and back covers, exceeding the given tolerance.

Solution:
TomTom used Moldex3D eDesign with Fiber simulation capability to investigate the root cause of warpage and the contribution of each variate to the total warpage of the product. Through the contributing factor study, TomTom was able to identify the major factors affecting the warpage. By combining all these key factors, TomTom was able to make the critical design decision quickly and accurately, and successfully reduces the risk of assembly problems.

Benefit:
- Minimized the assembly gap from 2.3mm to 0.3mm to meet dimensional specifications
- Increased yields by 92%
- Saved money and development time

Software used:
Moldex3D eDesign
- Fiber
- Flow
- Pack
- Cool
- Warp

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First Prize

Lite-On Technology Corporation

Improving the Warpage in a Scanner CIS Holder Part using Moldex3D and LS-DYNA


2015GITA_b01 Problem:
The holders, which are used to fix contact image sensors (CIS) in scanners, got warped during shipment due to the relief of internal stresses, causing the CIS holder detached from the scanner glass. This could have a critical impact on the depth of field and even cause some noise (speckles) on the image.

Solution:
To understand factors contributing to warpage, Lite-On utilized Moldex3D to simulate the effects of different design approaches, such as changes to gate locations, mold temperature and reducing materials. Comparing the analysis results, Lite-On determined which design had the minimum amount of warpage displacement. Next, Lite-On exported the simulation result of the optimal design to LS-DYNA using Moldex3D FEA interface and further investigated the internal strength of the part. This simulation, combined with structural analysis capabilities, helped Lite-On make informed decisions before making costly changes to existing part designs.

Benefit:
- Shorten product development cycle by 13%
- Significantly increase production yields by 99%
- Cut manufacturing costs

Software used:
Moldex3D Advanced
- FEA Interface (integrated with LS-DYNA)
- Flow
- Pack
- Cool
- Warp

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