Introduction

The Centre for Innovation in Polymer Engineering (PIEP), a non-profit research organization founded in 2000 at the University of Minho, Portugal, drives innovation in the plastics industry. Led by Silvia Cruz, PIEP used Moldex3D, a leading CAE simulation software, to develop a complex bicycle seat, achieving precise results despite challenging material and design requirements.

The Challenge

The project involved a bicycle seat with a polymer overmolding of a pre-brake insert, requiring dimensional accuracy. The highly loaded material was difficult to inject, and warpage defects were unacceptable due to strict tolerances.

PIEP utilized Moldex3D across the development process:

• Design Optimization: Virtual trials optimized part geometry, gate locations, and cooling systems, reducing physical iterations.
• Tool and Process Tuning: Moldex3D guided mold design and process parameters, identifying warpage risks early for strategic corrections
• Defect Reduction: Warpage and venting analyses enabled targeted solutions, ensuring dimensional accuracy.

Moldex3D delivered key benefits:

• Precision: Achieved strict dimensional tolerances for the bicycle seat.
• Efficiency: Virtual trials saved time by streamlining the development process.
• Reliability: Simulations matched real outcomes, addressing production challenges.

Conclusion

Since 2017, PIEP has employed Moldex3D’s evolving features, aligning with smart manufacturing and digital transformation to drive innovation in the plastics industry. Silvia Cruz notes, “Moldex3D supports our vision, and we look forward to continued collaboration.” In a complex bicycle seat project, Moldex3D was critical to achieving precision and efficiency, solidifying its role as a trusted partner.