Lecture    SM3244-P
The Effect of Mesh Density on the Accuracy of Meld-Line Predictions
Franco Costa, Edward Groninger + 1 co-speaker
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As General Motors relies more on Autodesk® Simulation Moldflow® software for upfront design for manufacturability, it has become apparent that the capability to accurately predict location and relative quality of meld lines is essential to eliminate costly tool re-work—work that is necessary to resolve surface quality and/or part performance issues. A research project was initiated under the auspices of continuous improvement to study the effect of mesh density—relative to obstruction size—on the ability of Moldflow to accurately predict position, length, and quality of a meld line. This class will review the findings of this research by using case studies to illustrate the impact of poor meld-line predictions on tooling strategy and explain how these tooling decisions could have been avoided through meshing technique. Proper mesh density for the accurate prediction of meld-line location and quality will be the next best practice enhancement to the GM Moldflow Specification, GMW16355.

Key Learnings

  • List potential limits in current meld-line prediction
  • Explain how mesh type effect affects meld-line prediction
  • Identify appropriate mesh density based on obstruction size and material
  • Describe potential impact to the product program of using improper mesh technique


 Franco Costa
Franco Costa
Dr. Franco Costa is a Senior Research Leader for the Autodesk® DLS-Simulation group. Over 20 years with Autodesk Moldflow®, he has contributed to the technologies of 3-dimensional flow simulations, thermal analysis, crystallization analysis, structural analysis, final net part shape prediction and multi-physics for the plastic injection molding simulation industry. Starting with Autodesk Moldflow as a doctoral scholar, Franco has moved through roles as a research engineer, development team leader, and manager and now leads key strategic research projects for the Autodesk Simulation technology group. Franco has presented at academic conferences in the field of polymer processing, acts as a referee on international journals, and often presents overviews of Autodesk Moldflow research technology directions at Autodesk Moldflow user meetings. Franco is based in the Autodesk R&D Center in Melbourne, Australia

 Edward Groninger
Edward Groninger
Ed is a Senior Manufacturing Engineer for the General Motors Global Paint & Polymers Center. He has 13 years of various injection molding experience. Beginning in 1999 as an injection mold tooling engineer, moving to process engineering in Spring Hill, and currently working on advanced vehicle interior systems. Recently becoming a certified Professional Moldflow user he is applying the software to lead GM's design for manufacturing activities.

 David Okonski
David Okonski

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