Industry Challenges

In the molding process, to use the appropriate machinery and equipment is very important. The production capacity can directly affect the quality. The mold, the injection machine and the working environment also impact the product quality in the injection factory. Manufacturers continuously test the mold and modify the design to ensure that the final production can meet customer needs in the development. Different mold design and product requirements also lead suppliers to choose different injection molding machines and process conditions.

Because of the complex product process, rising crude oil price, insufficient raw materials and the low-cost competition, we need to consider the relevance among the mold design, materials selection and equipment parameters in the plastic product development. But the injection mold is as a black box, the interaction of factors is invisible to the naked eyes. Therefore, how to optimize the production, achieve the efficient molding time, save the cost, and enhance the industrial competitiveness become the most complex and important issues.

Moldex3D Solutions and Benefits

Moldex3D has successfully bridged the communication gap between simulation and manufacturing. Moldex3D “Process Wizard” supports the properties of widely used molding machines in the injection molding simulation. Through the simulation, the developer can optimize the injection results for the correction of the mold design and molding conditions. The "computer mold testing" can quickly and effectively help developers to meet the demand, to avoid waste duplicate manufacturing, and to reduce development and production costs.

Moldex3D project can simulate with different product design and series process parameters and compare the differences between several runs to obtain the optimized molding results. In addition to the general injection, the mold design of the special molding and the injection machine of multi-screw combination can also be simulated by Moldex3D analysis. Moldex3D provides manufacturers with a complete assessment of the mold, injection machine, and even the optimal polymer materials selection before the production. It greatly enhances the overall product development efficiency.

Moldex3D Solves Tough Problems

Mold designer and mold maker

  • Challenges 1
  • Solution
    • The mold manufacturing budget will affect the overall product precision. If the product cannot meet the demand by process condition modification, the mold design may be changed to fill those requirements. But multiple mold revisions would cost a great amount of time and labor costs. Sometimes, the proprietor even sacrifices the product quality for controlling the budget.
    • Moldex3D injection simulation can analyze multiple runs of mold design geometry under the single molding process or find the optimal process conditions through the Moldex3D DOE analysis.

Mold designer and mold maker

  • Challenge 2
  • Solution
    • The life time is a common concern for the injection mold. The impact factors of mold life time include plastic material selection, mold processing quality, mold structure, the equipment using accuracy, the mold stiffness, lubrication conditions and so on. The manufacturers cannot examine and correctly prevent the defect or ensure the quality only by naked eyes and experience.
    • Users can import mold geometry and select materials (or customize the material parameters) in Moldex3D simulation, which provides complete results by molding analysis. Users can also observe the impact stress of the mold by melt flow, the final mold deformation and residual stress. These results provide mold makers to estimate the mold life time and product weakness for avoiding the damage by revising the mold.

The manufacturer of the injection machine

  • Challenge 1
  • Solution
    • In addition to the molding equipment stability and the required tonnage of the injection machine, the "screw design" is also another important factor for material selection and molding temperature settings. Therefore, the screw manufacturers often face the typical problems about the overall efficiency and stability of injection machine.
    • Moldex3D ScrewPlus allows user to estimate the general performance of screw design. It enables to trace back the features of screw and then update the process induced effects in the screw to enhance the accuracy for further injection molding process. This function assists users making more comprehensive estimation on the screw design.

The manufacturer of the injection machine

  • Challenge 2
  • Solution
    • In the recent years, the injection simulation software is usually used to verify the defects. Manufacturers can quickly improve injection molding conditions by CAE engineer’s simulation reports.
    • The diversity of interface set-ups between the mold-filling CAE software and the practical injection molding machine causes difficulty for CAE engineers to specify the parameters in CAE software corresponding to the actual UI icons in a real injection molding. Accordingly, this obstacle might interfere with the effective communication between CAE engineers and machine operators.
    • Moldex3D widely supports the properties of molding machines in the injection molding simulation, such as screw diameter and injection pressure. In addition, it delivers the operating page of real molding machine for users to import filling velocity and pressure response of the machine, further improving simulation accuracy with reference to real mold trials.

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