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Success Story

Autodesk Moldflow Used to Solve Mold Filling Issues

Autodesk Moldflow Used to Solve Mold Filling Issues

Customer challenge

During a routine molding process using a traditional runner system, the Dynamic Group noticed the filling progression near the end of the fill was causing issues, resulting in a cosmetic blemish. The flow front was traveling faster around the perimeter of the part, trapping gas in a non-vent region, thus resulting in a burn mark. The burn mark was caused by a combination of the filling progression front pattern as well as the part design.

Project goals

The priority project goal was to fully understand why the part design was causing a surface blemish and implement the right solution. To help resolve, Autodesk Solution Provider Beaumont conducted a mold filling simulation to determine a solution.

Solution

By using Autodesk Moldflow Insight (mold filling simulation), it was determined that increasing the part nominal wall thickness could further move the trapped air to a vented surface, thus eliminating the cosmetic defect.

Business outcome

Upon completion of testing, Beaumont determined that flow front would travel up and over the part, instead of filling around the sides. As a result, the trapped air was vented to the parting line, thus eliminating the burn mark and filling the part completely.

Conclusion

This is a great example where our customer was able to combine two of our services, our patented MeltFlipper runner design, as well as utilize Autodesk Moldflow Insight simulation to fix the problem. This is a prime example of how Autodesk Moldflow software can be used to experiment with wall thickness in order to prevent or solve part defects. Autodesk Fusion 360 (integrated CAD/CAM/CAE software) also makes it very easy to quickly edit the part dimensions then take that part directly into Moldflow.

Project summary

    Duration & delivery

  • 15
  • 2020-01-14

    Autodesk solutions

  • Moldflow Insight
  • Fusion 360

    Services provided

  • Simulation

    Customer industry

  • Design & Manufacturing
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Moldflow Analysis Validates GeorgeKo’s, Tetra’s Optimization Solution

When GeorgeKo Industries’ client decided to switch its ice tote manufacturing process from rotational to injection molding (resulting in a $52,000 annual savings in manufacturing costs), GeorgeKo’s client was hedging its bet on the ability to mold the parts defect free. As such, GeorgeKo guaranteed its client a finished product that would meet the client’s high quality standards. But after the initial production run of 500 pieces, the tote’s side walls began warping inward as much as a quarter of an inch on either side, which created problems in the end use of the product. This cost Georgeko over $5,000 in scrap and lost production time.

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