The Moldflow cooling analysis has been extended to gas-assisted injection molding and two-shot overmolding. The effects of part cooling can now be taken into account in filling and warpage, for both the first and second shot components.
Visualize the flow path of polymers to identify conditions that could result in surface defects. Identify which gate fluid particles entered, how far they traveled before freezing, and which path they took through complex geometry.
Simulate the rapid heating of magnetic components within the molds. Use electromagnetic induction to achieve a high-quality surface finish with no visible weld lines.
Achieve higher quality surface finishes by combining controlled valve gating with sequential valve gating.
Optimize the speed with which valve gates open and close for uniform flow and balanced injection profiles. Predict the effects of valve gates opening too quickly or slowly, and help avoid surface defects and hesitation effects.
Moldflow software helps you simulate and optimize thermoplastics injection molding process for your designs, using a vast database of thermoplastic materials. Select the best gate location, identify the processing conditions, and study the filling parameters.
Determine if you’re cooling the mold adequately, and then check for warpage. By incorporating Moldflow into your design process, you can validate product quality before investing in expensive tooling.
Molding processes you can simulate with Moldflow software include:
Simulate the warpage of the manufactured part to help ensure the end product's fit and function. Generate accurately compensated models for tooling or further geometry modification. In cases of excessive shrinkage and warpage, it's easy to isolate the underlying cause of the warpage (differential shrinkage in the part, mold cooling imbalances, or material orientation) so you can evaluate targeted actions and alternatives to address the issue. The Moldflow database contains grade-specific data to support the highest level of predictive accuracy.
Capture advanced cooling techniques and layouts, such as conformal cooling, as well as transient heat calculations. Iterate on the cooling channel layout and the cooling process to produce high-quality products with short cycle time. Simulate advanced cooling technologies, like rapid heating and cooling and conformal cooling. Evaluate the effect of highly conductive materials, as well as heating elements and thermal pins, on the cycle time and product quality.
Reduce or eliminate many production problems and defects by selecting the correct gate location. For more complex designs, use the Moldflow Gating Suitability Analysis for advice on a range of gate locations to find your optimal gate locations. The way molten plastic polymer flows through a mold can significantly affect the overall quality of a part. Use the Fill Preview tool to experiment with different gate locations to preview how the mold will fill.
Calculate and evaluate the fiber orientation, manufactured shape, and structural properties of your part. You can also export fiber orientation and mechanical results to an external structural analysis package to further investigate the strength of the finished part.
No matter which type of plastics you use, Moldflow Insight plastic injection molding simulation software can help you find the best molding conditions. Thermoplastics and thermosets are the 2 primary types of plastics used in manufacturing. They have distinct properties and are suited for different applications.
Select from different molding processes including:
Simulate how parts are filled and reduce molding defects, retooling, and redesign.
Perform structural tests using finite element analysis (FEA), and verify critical loads. The injection molding process influences the structural properties of the product, such as weld lines, fiber orientation, and material orientation.
If the product has a critical load case to meet, then you can perform a structural analysis test within the injection molding process to include in the analysis.
Visualize and understand how the part geometry and the location of injection points affect defects, such as weld lines and sink marks, as the part goes through shrinkage and warpage
Optimize the position of the injection points, the part geometry, and the molding process to minimize defects in highly visible areas. The position and depth of sink marks can be exported as .fbx files to Showcase and VRED software, so you can evaluate them in detail.
Moldflow injection molding software products provide the tools you need to transform your design concepts into produced parts.
Simulate the process of 2 sequential injections (or materials), visualize the impact on their relative behavior, and analyze the overmolding process. In two-shot sequential overmolding, different colored versions of the same material or 2 different materials are injected into the mold.
Use Moldflow to then assess warpage, relative temperature distributions of the materials, and the effect of plastic or metal inserts.
Use Moldflow injection molding simulation software to reduce optical quality issues, such as blurring or double images. Many factors influence birefringence, including the material, mold design, and molding conditions.
Moldflow tools help you predict optical performance issues in plastics.
Simulate one-directional core deflection on parts with inserts. See pressure differential around the core that could lead to core deflection, and use one-sided constraint to help with your analysis.
Cores and inserts shift during the injection molding process because of unbalanced pressures around the feature. The injection mold holds part inserts or cores in place by several methods. Sometimes the insert or core can move in 1 direction but not in the opposite direction. Use directional constraints to simulate the core or insert shifting in 1 direction, but not the opposite.
Use Advanced Material Exchange to transfer Moldflow data to Helius PFA projects for detailed composite structural analysis. Map material properties and fiber orientations from your Moldflow simulation to a structural package. Helius PFA uses the results to predict material nonlinearity and structural response.
Exporting "as-manufactured" simulation data from Moldflow enables a more realistic structural verification of your injection molded part early in the design cycle.
Perform mold-filling analysis of multicavity and family molds. Runner balancing ensures that all the cavities of a mold fill at the same time and with evenly distributed pressure.
Use Moldflow software to optimize the runner diameter for each cavity or segment of a mold, for even and more consistent results.
Understand the stability of your manufacturing process, and identify the major factors that influence your product defects or machine molding limits. Use design of experiments (DOE) analysis to determine which input process variables, such as mold temperature or injection time, can influence the quality of the part.
Run a series of analyses to investigate and optimize the molding process based on your defined quality parameters. Use the parametric study function in Moldflow to change molding parameters by a specified amount.
Then, visualize the effect of the parameter change on the part quality. This provides an intuitive way to understand the molding parameters that can help you achieve your quality goals.
Use Moldflow Insight software to simulate chemical blowing agents for creating plastic parts with an internal foam structure.
By using a combination of MuCell microcellular foam injection molding and core back technology from Trexel, you can dramatically improve the quality of foam structures. You can create a foam structure with more, bigger cells.
The result is a stiffer, lighter weight part than what can be achieved with conventional injection molding or with the MuCell (light weighting) process alone, without core back.
Simulate microcellular injection molding with 3D meshes. A fitted classical bubble nucleation model has also been added for all mesh types as an additional calculation option to the default constant nucleation density model.
Simulate the gas-assisted injection molding process to improve the location of gas injection positions, delay time, pressure profile, and packing time so you can achieve optimal gas penetration.
Validate the manufacturing process for your lightweight plastic components. With more focus on lightweighting, particularly in the automotive industry, validating manufacturability in the design stage is critical.
Create quality parts for applications that conventional injection molding can't address. Simulate compression molding for making very large parts that are otherwise difficult to mold. Simulate injection compression molding for low-stress, smaller parts, such as plastic lenses.
Simulate continuous fiber inserts made from composite materials or wood and analyze any overmolded part defects. In the automotive industry, for example, anisotropic materials, such as wood or continuous fiber composites, can be overmolded, and the simulation will show the final deformation of the overmolded part.
Simulate the injection of 2 materials into 1 cavity during a single molding cycle. Bi-injection molding simulation helps determine the relative distribution and location of both materials. These materials can be different or the same material with different colors.
Create decorative parts with a soft boundary between the 2 colors, and determine if the part meets the required specifications. Simulate the fill patterns to achieve the desired volume, distribution, and the relative weight of each material.
Simulate the encapsulation process of microchips, also known as packaging. Determine the optimal mold temperature, fill time, ram speed profile, and cure time. Moldflow Insight software provides tools for designing the encapsulation package, the tool, lead frame, and wires.
With Moldflow, you can run multiple simulations in the cloud simultaneously, while you continue to work on other tasks on your computer.
For example, if you're testing the setup of an analysis, use your local resources to iterate and optimize your setup. For longer, more computationally intensive simulations, use the cloud, and keep your local resources available for other work.
Automation can bring huge time savings to repetitive and time consuming tasks. Easily generate, share, and communicate your Moldflow analysis results with your internal and external teams. Use the report generator to create template reports in HTML, Microsoft Word, and PowerPoint.
Moldflow tools for analysis reports help you reduce the time spent on creating great looking professional analysis reports.
Run multiple analyses in the cloud with Moldflow Insight. Quickly solve larger analyses without compromising your local resource capacity.
Buy cloud credits to tap in to extra solving capacity when needed and to run Design of Experiments (DOE). Save both time and computing resources. Get results more quickly, so you can understand your design parameters sooner.
Cloud credits can be purchased by subscribers or maintenance plan customers. You can buy cloud credits from a reseller, directly from an Autodesk sales representative, or from the Autodesk Store through your Autodesk Account.
Improvements in the latest 2017 release of Moldflow injection molding simulation software include: streamlined workflows, ribbon customization, surface mesh modifications, synchronization of clipping planes in locked windows, tools for simulating local mesh density, and more.
SimStudio Tools is a direct modeler that helps you freely work on geometry with simple commands to move, edit, combine, or remove features. SimStudio Tools is a companion to Moldflow products and your CAD system.
SimStudio Tools reads in multiple CAD file formats, including Inventor, SOLIDWORKS, Creo, and many more. No matter what design program was used to create the model, you can work with it inside SimStudio to quickly make design changes and explore more design ideas.
Without affecting your original CAD model, SimStudio Tools lets you:
Once your model is ready in SimStudio Tools, push it directly to Moldflow or save it as a neutral file for any other work you may want to do later.
We’ve made several user requested enhancements to improve your productivity during pre- and post-processing. User interface improvements include permanent ribbon tabs, customizable and moveable command groups, and refined right-mouse contextual menus. Colors from CAD models are preserved upon import.
Additional enhancements let you:
We've added several new results and enhanced existing results to provide more insight into analysis results.
Results enhancements include:
New results include:
Easily create, repair, and refine meshes with new capabilities for mesh selection and node previews during remeshing. Usability improvements to the diagnostic navigator help you be more productive.
Moldflow processing is fast and accurate. Moldflow includes real-time, dynamic help wizards to help you make the best design choices. The help wizards in Moldflow can help with:
With Moldflow software, you have several options for how to best represent the product. Large, thin-walled parts are best represented using midplane and the patented Moldflow Dual Domain technology, while thicker parts are best represented with a 3D mesh.
Choose the best material for your product. The extensive databases of materials in Moldflow help you simulate many different materials for injection molding. The databases update continuously and include more than 9,500 plastics that are characterized for injection molding simulation. Several databases also include parameters such as coolants, mold materials, and injection molding machines.
Add frequently used or customized materials to the database for your records. Combined certified materials rate the confidence level of the material data for filling, packing, and warpage applications. Confidence levels are denoted by gold, silver, and bronze quality indicators.
Moldflow Insight Premium and Moldflow Insight Ultimate solvers enable you to run up to 3 analyses simultaneously, so you can analyze several results at the same time. In addition, your team can increase productivity by having up to 3 people run their analyses at the same time.
Streamline your simulation process. Create custom tools to reduce repetitive sets of tasks or to build customized workflows.The Moldflow Insight user interface (Synergy) includes the API automation layer based on a simple Visual Basic Script (VBS).
With no previous experience, you can:
You can even use a script from a third-party application to view, for example, a result within a specific design tolerance.
Import native CAD models, CAD translations, and neutral files directly into Moldflow software, no matter which CAD system was used to create them. You can also import meshes from different FEA tools, then export analysis results for further use in structural analysis programs. Use multiple native files for design optimization.
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