Compression molding is one of the earliest forms of molding. It is typically used for thermoset materials, but can be used with thermoplastics. The advantages of compression molding include more isotropic fiber distribution, dimensional stability, and surface finish. Compression molding can also support large part sizes, and it has a tendency to produce fewer knit lines. Injection-compression molding is a combination of injection and compression molding. The process keeps the advantages of injection molding and combines them with the advantages of compression molding. In this class, we highlight the advantages and limitations of both processes. We also discuss, in detail, the implementation of the processes using Autodesk® Simulation Moldflow® Insight software.

This class is about the experiments and simulations related to the microcellular injection molding. The experiments are part of the research done at the Microcellular Plastics Manufacturing Laboratory at the University of Toronto. We will present 3 topics related to the experiments. The first will be on the visualization studies on the bubble nucleation and growth. We will examine the effects of process conditions. The second will be on the use of mold opening (core-back) for the microcellular injection molding. The third will be on the effects of bubbles on the fiber orientation in the microcellular injection molding. We will use some of the experimental results (such as bubble nucleation/growth and the mold-opening experiment) in the simulation with  Moldflow Insight software. We will discuss the correlation between the experimental and simulation results, and we will also present some case studies related to microcellular injection molding and core-back processes.

This presentation will introduce recent and current research topics related to the Autodesk Moldflow injection molding simulation solvers, including the prediction of final part shape after molding, the behavior of the polymer melt during cavity filling, pack and cooling and the prediction of visual defects which may results in the molded part. In particular, improvements in the warp prediction accuracy for 3D model geometries by making use of measured shrinkage calibration data will be discussed, as well the elimination of model size restrictions for 3D warp analysis. Improvements in accuracy of Dual-Domain corner effects warpage will be demonstrated along with options for examining plastic part deformation after assembly.

The Autodesk® Moldflow® product team and the University of Bradford have a long-standing collaboration investigating key injection molding effects such as fiber orientation, residual stresses, warpage, post-injection product performance, heat transfer, and feature replication. This class will focus on academic and industrially relevant components from the initial design phase, through production using both conventional- and micro-injection molding, to final product property assessment in terms of mechanical performance, geometric tolerances, and feature replication.

Just because you designed a plastic part, doesn’t mean it can be manufactured at scale. Product design has a significant impact on the cost and timing of part manufacturing. In this class, you’ll learn how to identify and address costly manufacturing issues with Injection Molding Simulation in Autodesk Fusion 360.

Rapid prototyping is increasingly being used in the production of injection molding inserts. This technology enables for much lower lead times in prototype and low-volume production. However, the thermal and structural properties of prototyped inserts are different than those of conventional machined inserts. The focus of this class is to use Simulation Moldflow Insight software to evaluate the thermal and mechanical behavior of rapid prototyped injection molding inserts. We will look at 3 sets of inserts that were analyzed using different manufacturing techniques and materials, which included selective laser sintered (SLS) bronze, PolyJet ABS-like material, and conventional machined stainless steel. Molding trials were performed on the inserts, as were computer simulations. The experimental and simulated results were compared for the thermal gradient, structural performance, part warpage, and part shrinkage.

The optimization of injection molding process parameters and part designs is usually a manual process, utilizing ad hoc methods and dependent on user expertise. OmniQuest’s Iliad Design Exploration and Automation Studio now features a dedicated interface with Moldflow Insight software, bringing enhanced optimization and design automation capabilities to injection molding simulation. This interface creates the opportunity for design space exploration through studies such as 1) optimization, 2) response surface modeling to establish mathematical relationships between process parameters, 3) design of experiments, and 4) reliability analysis. By using Iliad’s integration capability and direct interfaces to Ansys Workbench, Python, and other CAE software, you can also control the complete design cycle using a single platform, including running macros and additional stress analysis. We will showcase how Iliad delivers real cost benefits to Moldflow Insight users through multiple case studies.

The metal injection molding (MIM) process is a combined one of the injection molding and powder metallurgy, and it is used to manufacture complex metallic parts. Now Moldflow Insight software can simulate the MIM process and predict different common defects from the MIM process, such as weld lines, air traps, and "black lines" caused by the powder segregation. The Moldflow Research and Development Team has teamed with AAC Technologies (the world's leading comprehensive microcomponent technology provider) to simulate this process. This class will introduce the basic theory, challenges, and actual cases to show the MIM feature in Moldflow Insight software. Finally, an excellent correlation was achieved with validation data provided by AAC. This session features Moldflow Insight.

Design is rarely a perfectly linear and straightforward process. Often a single tool cannot accommodate all the workflows and even when it does, it is rarely the right fit. By leveraging the different tools within the Autodesk PDM collection (Autodesk Inventor, Fusion 360, Desktop connector), designers and engineers can now design, make and collaborate on products to reduce the lead time faced in today's manufacturing. This course will cover the complete workflow when designing parts for formative manufacturing - Injection molding. From making a mold in Inventor to validating your part for Injection molding in Fusion 360, the Autodesk PDM collection helps you connect these workflows right on your Desktop using Fusion 360 desktop connector.

This class will discuss different approaches to injection molding simulations with  Moldflow Insight software. Individual users have been given a problem to solve using Moldflow software. We will present their approaches, and then we will compare and contrast the different approaches. Analyisto e analyisto— it’s a showdown you don’t want to miss. Get ready to rumble!

The University of Bradford has been using Autodesk Simulation Moldflow software for many years to investigate key injection-molding effects such as fiber orientation, residual stresses, warpage, post-injection product performance, heat transfer, and feature replication. This class builds on our Autodesk University 2011 class and covers the experimental and computational analysis of short- and -fiber reinforced components during injection molding, along with thermal investigations of the micromolding process.

This class will discuss the requirements and workflow for simulating flow imbalances in injection molding that are caused by shear heating in branched runner systems. Validation case studies will also include the MeltFlipper design, as well as in-cavity flow imbalances that lead to race-track effects. This class will focus on the use of the Autodesk Moldflow Insight software.

During this class we will address major issues related to 3D shrinkage and warpage analysis in injection molding. We would like to start with an introduction of mechanism of shrinkage and warpage. We will discuss the generic shrinkage model and its limitations. We will also present 3D thermo-viscous-elastic residual stress model and thermo-viscoelastic residual stress model. Finally, we will explore some advanced topics, such as corner-effect, in-mold shrinkage, stress relaxation, buckling, and large deflection analysis.

Microcellular Injection Molding (MuCell) is a mechanical foaming process used to improve the performance/weight characteristics of an injection-molded part. This class focuses on the Microcellular Injection Molding module for Autodesk® Simulation Moldflow® Insight. We explore how well the module correlates with real-world molded samples, determine the best approach for using the module for a brand new mold, and discuss any limitations to the module.

This class will review new functionality in Simulation Moldflow Insight software and discuss current research directions in the development of Simulation Moldflow software. Capabilities covered will include microcellular foaming, improved fiber orientation and fiber breakage calculations, enhanced wall slip calculations, velocity-controlled valve gates, induction heating, particle traces, user routines, the influence of mold deflection, and meshing enhancements. There will also be an overview of new research collaborations in the area of injection molding simulation research.

Generative design is a hot topic, but existing manufacturing methods like casting and injection molding seem to be hiding behind the curtains. This presentation will focus less so on additive manufacturing and more so on mass manufacturing methods currently being used industry wide. By leveraging existing generative design technology with casting and injection molding best practices, we can re-shape how current product design for manufacturing workflows can be achieved. By demonstrating the capabilities of new generative design technology, this talk will expose the new feature enhancements showcasing a realistic approach to the manufacturing and product design world which can be implemented into product design and manufacturing workflows today.

This class will review new functionality in Autodesk® Moldflow® Insight software that represents the current research directions in Moldflow development. We will discuss several capabilities, including 3D injection compression molding, conformal cooling support, 3D heater elements, crystallization analysis, breakage of long fibers and properties of LFT composites, bi-injection molding, multiple cylinder support for 3D gas injection, buckling analysis for 3D warp, improved wall slip calculation, viscoelastic residual stress, ejection force prediction, and analysis of mold fatigue.

This class will discuss the tools available in Autodesk® Moldflow® Insight for simulating the dynamic temperature changes experienced in the mold during an injection molding process by using the Cool Finite Element Method (FEM) functionality. Topics covered will include modeling requirements, process setup and workflow, theory, result interpretation, and validation examples. Focus will also be given to new functionality available in the Scandium Technology Preview supporting dual-domain part models, thermoset molding and variable coolant inlet temperature processes, including Rapid Heating and Cooling of the Mold (RHCM), also known as Rapid Temperature Cycling or Variotherm. In addition, examples will be shown to demonstrate how to model complex 3D cooling channels (conformal cooling).

Injection-compression molding (ICM) is a process that results in reduction in molding pressure and the clamp force that is required to mold. Since the part experiences lower pressure gradient during molding, the residual stresses induced due to flow of material is reduced considerably. Due to this, and if everything else is kept constant, the final part warpage gets lowered significantly. This reduction in molded-in stresses also improves optical properties, which is important for applications requiring transparency. Also, ICM as a process is being used for molding of large parts, which otherwise require high tonnage presses to mold them. In this class, we investigate the influence of various parameters of the ICM process on final part warpage. The part considered here is a 2K molded part where the first shot can be molded using the conventional molding process. The second shot is injection-compression molded, keeping the first shot as a plastic insert.