10 Real-World

Injection Molding Simulation

Case Studies
TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CASE 1 SKF Technologies India . . . . . . . . . . . . . . . . . . . . . . . . 4

Solving Aesthetic Issues of Electronic Component Insert Molding

CASE 2 The Ohio State University . . . . . . . . . . . . . . . . . . . . . . 7

Using Novel CAE Tools to Verify Warpage and Refractive Index of Optical Parts

CASE 3 Garmin Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Simulating and Improving Warpage of a GPS Watch Part

CASE 4 LMT Mercer Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Family Mold Optimization to Reduce Cost and Improve Quality

CASE 5 Linear AMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Using Moldex3D Conformal Cooling Analysis to Reduce 69% Cooling Time

CASE 6 TomTom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Moldex3D Helps to Solve Deformation Issue of a Navigation System Part

CASE 7 FARPLAS A.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Using Moldex3D to Overcome Difficult Molding Issues in Multi-shot Injection Molding

CASE 8 Faurecia Interior Systems . . . . . . . . . . . . . . . . . . . . 31

Utilizing Moldex3D Analyses to Make Confident Decisions on Product Design Optimization

CASE 9 Proplast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Moldex3D Simulation Results Facilitates Implementation of MuCell® Technology

CASE 10 Plazology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Attaining Optimum Process Settings with Moldex3D DOE Analysis to Improve Part Quality

10 Real-World Injection Molding Simulation Case Studies | 2

INTRODUCTION

In recent years, we’ve witnessed a change in how companies use injection molding
simulation. In the past, most companies simply used simulation software to
diagnose problems that already occurred. As the simulation technology became
more mature and the awareness of upfront simulation began to increase, we finally
see companies extract the value of simulation by incorporating the technology early
in the design stage. This helps designers make critical design decisions with
confidence and shorten the design-to-manufacturing cycle.

This eBook is a collection of real-world case studies from our clients spanning on a
wide range of industry sectors, company sizes and business needs. Here you will
see how other companies like yours have met and overcome challenges coming
from all levels of manufacturing processes with the aid of simulation.

We hope you find value in these case studies that demonstrate why injection
molding simulation plays a pivotal role in the design decision-making process, and
how you can apply it in real life scenarios.

Sincerely,
Moldex3D Team

10 Real-World Injection Molding Simulation Case Studies | 3

Solving Aesthetic Issues of Electronic Component
Insert Molding through Moldex3D

Customer: SKF Technologies India Pvt Ltd.

Country: India
Industry: Electronics
Solution: Moldex3D Advanced

SKF has been a leading global technology provider since 1907. Their
fundamental strength is the ability to continuously develop new
technologies – then use them to create products that offer competitive
advantages to our customers. We achieve this by combining hands-on
experience in over 40 industries with our knowledge across the SKF
technology platforms: bearings and units, seals, mechatronics,
services and lubrication systems. Our success is based on this
knowledge, our people, and our commitment to SKF Care principles.
(Source: http://www.skf.com/)

Image Courtesy of SKF Technologies India Executive Summary

Every industry has its unique challenges, but virtually all industries
share the goals of increased machine uptime, reduced maintenance,
improved safety, energy savings and lower total cost of ownership.
With expertise in a wide range of disciplines and decades of
experience as a technical partner to both equipment manufacturers
and end users in every major industry, SKF is delivering not just
products but total integrated solutions that help our customers
achieve their goals.

The SKF sensor unit in this case includes electronics that need
adequate sealing mainly for preventing liquid ingress and mechanical
protection. This can be achieved by potting and over molding. The
project involves analyzing the over molding of electronics, connectors
and cable with printed circuit board (PCB) material as inserts.

10 Real-World Injection Molding Simulation Case Studies | 4

Challenges
　● To reduce design iteration and prototyping times.
　● Identify the defects and correlate the simulation results with actual product failures for design optimization.
　● Reduce product development cycle time.

Solutions
Moldex3D Designer and Project helped to create BLM mesh and run simulation successfully. Moldex3D technical
support team helped to explore the tool and fix the problems whenever required in minimum time. As SKF has inserts
with small electronic components, cable, connector’s etc., achieving good quality mesh was a big challenge. This was
achieved using BLM mesh tool as recommended by Moldex3D team.

Benefits
　● Optimized the process parameters.
　● Identified defects and suggested improvement with respect to design modification and process settings.
　● The simulation results helped to investigate the reason for product failure.

Case Study
In the first phase, the objective was to carry out low pressure over molding simulation for single cavity molding. With
current process setting identification of design and process defect was one of the main requirements. The
observation must be made to find correlation with the existing manufactured part. Phase 2 objective was to realize a
rheology over molding study to check the feasibility of molding 2 parts of the same product and define the best
position of the injection point, best runner and gate design and dimension of cooling circuit. At the same time, the
defect identified in the 1st phase must also be fixed.

The technical centre of SKF used Moldex3D Advanced solution to simulate the molding scenario of the original
design. The meshing issue of the small electronic component and cavity was solved by BLM meshing. Through
Moldex3D simulation results, they found filling issues in some regions on the part due to the gate location. There was
also flow hesitation in thin wall areas. In addition, SKF was able to identify the internal residual stresses on the
electronics during molding process. Finally they were able to optimize the process parameters to get the best cycle
time and operate at the lowest possible pressure.

There was a design change in the gate type and location of the 2-cavity mold design. The runner system dimension
and design was also changed respectively taking into account the defect observed in the first phase. This resulted in
smooth material flow without hesitation effect and filling was better compared to the existing design (Fig. 1). The
process was optimized to achieve the best cycle time with reduced cost and operated at low pressure. These were
done by performing various runs and then compare the graph to finalize the best solution. Simultaneously, the
temperature, pressure and thermal residual stresses around the electronic component were also controlled.
Gate 2

l
osa
g op
tin Pr
is w
Ex Ne
Gate 1

Fig. 1 We can observe the flow is not uniform in the original design (left) and there is flow
hesitation in some areas like connector area. In new proposal (right) with 2 gates, we can
observe the flow is uniform and the flow hesitation has almost been eliminated.

10 Real-World Injection Molding Simulation Case Studies | 5

The simulation was generated for the existing design with the help of Moldex3D. All the observation was noted and
the action plan was created with respect to process changes and design changes. The results obtained from
simulation for the existing design were close to the real scenario. This was verified with the process data sheet from
the production. The identified defects in the existing design were also observed in the existing product as shown in
Fig. 2. After the design changes, Moldex3D was used to simulate both the original design and the optimized design.
The design was optimized taking into account all the identified problems from the existing design. Additionally, the
cycle time was optimized to reduce production time and cost. When compared with the actual mold trial results,
SKF’s technical centre found that Moldex3D simulation analysis results had strong correlation with the real scenario.

Fig. 2 High correlation between simulated and actual manufactured part is shown. A sink
mark is identified on the simulated model (left) and the same result is visible in the
prototyped part (right).

Results
Through Moldex3D analysis, SKF could clearly understand the filling behavior and predict probable defects due to
process parameters and design deviations prior to prototyping and production. This saved a large, valuable amount
of product development cycle time due to early investigation using Moldex3D tool. The accuracy of Moldex3D
simulation analysis was verified with the actual manufacturing process sheet and visual inspection. The result helped
their technical centre to optimize the process parameters, identify and fix defects in product and also correlate the
cause of product failures at end application with the identified defects.

10 Real-World Injection Molding Simulation Case Studies | 6

Using Novel CAE Tools to Verify Warpage and
Refractive Index of Optical Parts

Customer: The Ohio State University

Country: U.S.A
Industry: Educational/Academy
Solution: Moldex3D Advanced, Optics Module

For 144 years, The Ohio State University’s campus in Columbus has
been the stage for academic achievement and a laboratory for
innovation. It is also one of America’s largest and most
comprehensive. As Ohio’s best and one of the nation’s top-20 public
universities, Ohio State is further recognized by a top-rated academic
medical center and a premier cancer hospital and research center.
(Source: https://www.osu.edu/)

Image Courtesy of The Ohio State University Executive Summary

Microinjection molding is a mass-production method to fabricate
affordable optical components. However, it often results in part
deformation and uneven refractive index distribution. Finite Element
Method (FEM) was employed to understand the influences of
injection molding on the optical performance of freeform Alvarez
lenses. The optical wavefront patterns were evaluated using an
interferometer-based wavefront measurement system. This setup
utilized an optical matching liquid to reduce or eliminate the lenses’
surface power such that the wavefront pattern with large deviation
can be measured by a regular wavefront setup. Moldex3D was also
applied to help understand how the potential issues, surface
deformation and refractive index variation, can influence the
wavefront change.

10 Real-World Injection Molding Simulation Case Studies | 7

Challenges
　● Quality issues for optical applications: thermally-induced shrinkage, non-uniform refractive index, and birefringence
　● How to use FEM to model the molding process
　● How to analyze process’ influences on optical performance of injection molded freeform optics
　● How to fundamentally verify simulated optical performance

Solutions
Moldex3D provides two most critical, accurate simulated parameters: part warpage and refractive index for freeform
optics. It provides true 3D results with consideration of filling, packing, and cooling stages too.

Benefits
　● Improve understanding of the quality control of microinjection molded freeform optics
　● Visualize and obtain the value of geometry deformation and refractive index variation
　● Learn how the surface deformation and refractive index variation affect the wavefront change

Case Study
The objectives of this study are to compute geometry deformation and refractive index variation from FEM model of
the freeform optical element, to measure the wavefront pattern which indicates the optical performance of the
microinjection molded lens, and to compare the simulation with the measurement results that will give better
understanding for optimization of the optical performance via CAE approaches.

Moldex3D simulation was performed using a 3D FEM model, created using HyperMesh beforehand, in order to
obtain the results of part deformation and refractive index distribution (Fig. 1). The material used in the simulation
was PMMA Plexiglas V825. The software can detect and show the surface deformation of this freeform optics and the
uneven distribution of the part refractive index (Fig. 2). Then, these results were verified and compared with the
measured ones by which the aberrations could be calculated.

injection inlet

Node(i,N)

vertical line at (xi ,yi ) Node(i,1)

Fig. 1 The 3D meshed model is made of 10-layer prism elements (left) with
a runner system shown on the right.

10 Real-World Injection Molding Simulation Case Studies | 8

 Fig. 2 The microinjection molded Alvarez lens (left) and the visualization of
its surface deformation (right).

There was no change made to the original design since the main purpose of this study is to verify the simulation
results by the measured ones (Fig. 3 & Fig. 4). Any changes to optimize the injection molding process are planned to
be part of the future tests of this study.

Fig. 3 The simulated (left) and measured (right) surface deformation of

the microinjection molded Alvarez lens.

Fig. 4 The simulated (left) and measured (right) refractive index distribution of
the microinjection molded Alvarez lens.

10 Real-World Injection Molding Simulation Case Studies | 9

Furthermore, the wavefront patterns of this freeform lens were also verified. The verification compared the nominal
wavefront pattern of an undeformed Alvarez lens which had uniform refractive index with the measured wavefront
pattern of the microinjection molded Alvarez lens. The measurement setup utilized a transmission interferometry
setup. The lens was immersed in an optical liquid with controlled refractive index. If the controlled refractive index of
the optical liquid matches to the nominal surface refractive index of the lens material, the measured wavefront pattern
indicates the refractive index variation inside the lens. On the other hand, if the controlled refractive index is not equal
to the nominal refractive index of the lens material, the measured wavefront pattern is primarily determined by the
surface power.

Fig. 5 The nominal wavefront (left) and the measured wavefront (middle) are compared to
show their difference (right).

The results show that the nominal wavefront deviation is 15.89 λ, while the measured one is 15.8 λ. The maximum
local difference of these two wavefront patterns is less than 5%, and the major differences come from the center and
corner areas. Indeed, the cause of this difference is the combined effect of both surface deformation and refractive
index variation occurring in the actual microinjection molded part, once predicted by Moldex3D software beforehand
as well.

Results
Through Moldex3D analysis, both part warpage and refractive index of the microinjection molded freeform optics
could be accurately obtained and visualized. This helps to give better understanding of how the potential issues, such
as surface deformation and refractive index variation, can influence the wavefront change. The difference between
nominal wavefront pattern of undeformed Alvarez lens with uniform refractive index and the measured one of
microinjection molded Alvarez lens, which had deformed shape and non-uniform refractive index, was found out to be
primarily determined by the combined effects of those two issues. In addition, true 3D results of filling, packing, and
cooling stages are also provided from the simulation. Importantly, the use of this software also helps to significantly
reduce the product development cycle time. Last but not least, Moldex3D provides an opportunity to conduct several
future tests for this study, such as stress and birefringence analyses, insert molding for integrated optics, and
optimization for the injection molding process using the DOE feature that will reduce the wavefront difference.

10 Real-World Injection Molding Simulation Case Studies | 10

GARMIN Reduced Thousands of Dollars Cost by
Improving Watch Product Warpage through Moldex3D

Customer: Garmin Corporation

Country: Taiwan
Industry: Electronics
Solution: Moldex3D Professional

As a leading worldwide provider of navigation, GARMIN is committed

to making superior products for automotive, aviation, marine, outdoor
and fitness markets that are an essential part of the customers’ lives.
(Source: http://www.garmin.com/)

Executive Summary
Waterproof is a key function in Garmin’s product design. The molding
scenario has to be accurately set in order to control product
deformation, air traps and product size. If the product size is not
properly controlled, the watch will tend to leak under high pressure
Image Courtesy of Garmin Corporation environment because of deformation. Thus, Garmin Corporation
decided to utilize Moldex3D to find the optimal product design to
improve waterproof.

Challenges
　● Part warpage
　● Poor waterproof due to warpage

Solutions
Utilizing Moldex3D Professional Package to obtain the optimum
process settings in order to successfully improve the product’s
warpage problems.

10 Real-World Injection Molding Simulation Case Studies | 11

Benefits
　● Reduced 2 or 3 mold revision times
　● Saved NTD$200,000 ~ NTD$300,000 worth of mold revision costs
　● Reduced 40,000pcs of the product capacity lost
　● Improved warpage by 75%
　● Improved the waterproof yield rate by 15%

Case Study
The objective of this case is to determine the gate location of a GPS watch in order to reduce the warpage problems
in the middle of the part. The warpage of the original design is about 0.4mm. Garmin utilized Moldex3D to simulate
the molding scenario of the original design. Through Moldex3D simulation results, Garmin found out that using
traditional injection molding method, high warpage would occur in the middle of the part. This molding defect would
have a direct negative impact on the product’s functionality and physical appearance. Thus, in order to solve this
problem and produce high-quality products, Garmin decided to change the gate design. Therefore, they proposed
two new designs of revising the gate location (Fig. 1).

Original Option-A Option-B

Fig. 1 The gate design revisions, Option A & B compared to the original design

After the design changes, Garmin used Moldex3D to simulate the original design and the revised designs. The
analysis results of the original product design showed (Fig. 2) the Z-axis warpage would reduce from 0.36mm
(original) to 0.06mm (Option-B). And the actual mold trial results showed the warpage would reduce from 0.4mm
(original) to 0.1mm (Option-B). Furthermore, Garmin found that Moldex3D simulation analysis results were strongly
correlated with the results of the actual mold trials (Fig. 3).

10 Real-World Injection Molding Simulation Case Studies | 12

 Warpage of Z-axis
Original: 0.36mm Option-A: 0.25mm Option-B: 0.06mm

Fig. 2 The Z-axis warpage simulation results of 3 designs

Warpage of Z-axis
Original: 0.4mm Option-B: 0.1mm

Fig. 3 The Z-axis warpage mold trials of the original and the optimized design

Results
Through Moldex3D, Garmin was able to evaluate how molding scenario affected concentricity and flatness of a watch
under different gate locations and numbers. Thus, Garmin could successfully improve the flatness as well as
assembly yield rate and waterproof rate. Moldex3D’s 3D mesh technology also made the simulation results more
consistent with the actual results in manufacture. Ultimately, Garmin was able to decide the optimal design within
limited development time, avoid repetitive mold trials, and reduce costs.

10 Real-World Injection Molding Simulation Case Studies | 13

Earning Total Savings of $11,500 on Mold Work for
LED Products with Moldex3D

Customer: LMT Mercer Group, Inc.

Country: USA
Industry: Consumer Products
Solution: Moldex3D eDesign

LMT Mercer Group, Inc., the leading manufacturer of vinyl fence,

deck, and railing accessories in the US and Canada, operates three
manufacturing plants in New Jersey and Ohio. LMT operates more
than 30 state-of-the-art injection molding machines equipped with
servo-robotics and nitrogen gas-assist capabilities. It has used
Moldex3D for their product development process optimization since
2013. (Source: http://lmtproducts.com)

Executive Summary
Image Courtesy of LMT Mercer Group, Inc.
Two lighting parts, made from the same material, were both produced
in the same mold to reduce the costs. However, their sizes were quite
different, so unbalanced filling occurred. Through Moldex3D, the
other issues, such as sudden spike in clamping tonnage and
overworked cooling channels could also be detected. Therefore,
optimization on runner/gate and cooling systems were made that
resulted in the eliminations of unbalanced filling and sudden tonnage
spike, the reductions of both clamping force and cooling time, and the
improvements of both cooling efficiency and part flatness. In addition,
substantial time and cost savings could be achieved too.

Challenges
　● To complete the filling process at the same time for both parts
　● To ensure the runner/gate configuration and cooling channel sizes
and locations that would not cause excessive warpage on the parts

10 Real-World Injection Molding Simulation Case Studies | 14

Solutions
Moldex3D provides the analyses for filling, packing, cooling, and warpage in which the effects of any design changes
and modifications in runner/gate and cooling systems on the improvements on filling time, cycle time, cooling
efficiency, and part flatness can be observed beforehand.

Benefits
　● Succeeded in reducing the clamping tonnage required at the end of packing from 225 ton to 175 ton which
reduces costs of the part too due to smaller press size required
　● Succeeded in having both parts to be fully filled at 1.28 s; the initial runner and gate design resulted in full filing
times of 1.07 s and 1.28 s for the smaller and larger parts, respectively
　● Obtained optimized cooling channel design which reduced cycle time through reduced maximum cooling time
by 11.99% and made the cooling efficiency difference only 13.759% from 25.452%
　● Improved flatness of the smaller part by 2.56% and of the larger part by 6.18%
　● Earned total savings of $11,500 for mold work and sampling charges

Case Study
The objectives are to reduce the cost of parts by both reducing the press size required through optimized runner/gate
and reducing the cycle time, to keep part flatness within acceptable quality limits, and to accomplish all these goals
before the making of the mold so that the tooling and sampling costs could be reduced.

Moldex3D eDesign was utilized to mesh the model which contains two different cavities in one mold; the smaller part
was for LED board holder, whereas the larger one was for light reflector. Moldex3D became a powerful tool to detect
and identify unbalanced filling through melt front time, sudden spike in tonnage of the clamping force, maximum
cooling time, overworked cooling lines, and the Y-displacement for both parts.

The changes include runner layout and cooling system as illustrated and explained in Fig. 1 and Fig. 2.

Fig 1. The original design has the edge gate for the smaller part and jump gate for the larger part (left),
while the revised design keeps the jump gate for the larger part but uses the extended jump gate for
the smaller part (right).

10 Real-World Injection Molding Simulation Case Studies | 15

 Fig 2. Different from the original design (left), the revised design (right) splits the connected loop cooling
channel for the larger part’s top and bottom sides and add a cooling channel for the larger part’s bottom side.

As shown by Moldex3D’s simulation results, the smaller part has been fully filled too early compared to the larger
part. The revised design makes the flow path for the smaller part longer from its runner and gate design, so its filling
time can catch up with the longer filling time of the larger part (Fig. 3).

Short Shot

Short Shot

Short Shot

Short Shot

Fig. 3 The comparison between the melt front time of the original design at 74% filling (top) and the
revised design at 96% filling (bottom) shows that the unbalanced filling for both cavities has been solved.

10 Real-World Injection Molding Simulation Case Studies | 16

The next result is the cooling time in which the maximum cooling time can be reduced from 21.009 s to 18.489 s via
optimized cooling system design. In other words, the cycle time could be reduced as well. The last result is the
Y-displacement which represents the part flatness. The original design results in maximum displacements of 0.1981
mm and 0.6985 mm for smaller and larger parts, respectively. Meanwhile, the revised design can reduce the
maximum displacements for both smaller and larger parts to 0.1930 mm and 0.6561 mm, successively.

Fig. 4 The distributions of the Y-displacement for both of the smaller and the larger part show that the
original design (left) has larger displacement than the revised one (right).

The design revision was verified by the actual injection molded parts. During initial mold sampling, the process
conditions from Moldex3D were given to the process engineer. The process engineer made short-shot parts just
before the end of the filling. The injection molded short-shot parts has identical short shot locations to the ones in
simulation results as shown in Fig. 5.

Short Shot Area

Short Shot Area

Fig. 5 The actual injection molded parts for the revised design for larger part (left) and
smaller part (right) have identical short shot locations with the simulation result in Fig. 3.

Results
This project was a success in which the objectives of both reducing the part cost and improving the quality of the
finished products had been accomplished. The design revision was made by modifying the runner/gate design and
optimizing the cooling channel layout before the mold steel was cut and shaped. With the ease of use that Moldex3D
offers, various designs were tested quickly to find the best results without having to make expensive changes to the
tooling after the fact. By improving the mold and part designs with the assistance of Moldex3D, time to market and
tool sampling had been streamlined. Thus, substantial time and cost savings could be achieved as well. Besides, the
validation comparing the simulation result with actual injection molded parts showed that both filling results were very
identical.

10 Real-World Injection Molding Simulation Case Studies | 17

Linear AMS Utilizes Moldex3D Conformal Cooling
Analysis to Reduce 69% Cooling Time

Customer: Linear AMS

Country: USA
Industry: Mold Making
Solution: Moldex3D eDesign

Linear Mold& Engineering was founded in 2003. By pushing

the limits to develop new uses, testing new materials, and
creating new production processes for their customers, Linear
helped establish an emerging market for delivering precision
tooling, molding and industrial parts. In 2015, global
engineering industry leader Moog, Inc. purchased controlling
interest in Linear, rebranding the company to Linear AMS
highlighting their additive manufacturing solutions capabilities,
but maintaining operations as a separate company. (Source:
http://www.linearams.com/)
Image Courtesy of Linear AMS

Executive Summary
In plastic injection molding, the cooling process is the longest
portion, often prolonging the total cycle time. In the supply
and demand world, the ability to produce parts faster and
more efficiently is always the top priority for the
manufacturers. However, conventionally drilled cooling lines
in molding tools have many limitations in shortening the cycle
time. In order to solve this present issue, Linear AMS decided
to propose a new conformal cooling system and utilized
Moldex3D to validate the design. In the end, they successfully
reduced the cooling cycle and had more confidence while
helping their customers solve cooling issues.

10 Real-World Injection Molding Simulation Case Studies | 18

Challenges
　● Limitations of conventional cooling design resulted in unacceptable, long cooling times
　● Designing an effective conformal cooling system to reduce cooling time

Solutions
Utilizing Moldex3D eDesign to design the optimum conformal cooling layout in order to successfully reduce the
cooling portion of the cycle time

Benefits
　● Reduced cooling time by 69%
　● Developed a competitive advantage in the market

Case Study
This case features a rifle stock arm brace part. Linear AMS’ long term objective is to design a conformal cooling
system to assist customers to reduce cycle times. This project’s specific objectives primarily focused on reducing the
cooling portion of the cycle time.

First of all, they needed to produce a higher volume of parts, but they were not able to add additional molds and
presses into the process. The fill/pack process had been successful prior to Moldex3D’s involvement, so warpage
was not an issue. When they utilized Moldex3D to analyze the conventional cooling process (Fig. 1), they found
serious heat accumulation in the middle area as well as the shaft (Fig. 2).

Cooling in center No cooling

Fig. 1 Original Cooling Channel Design

Original Design Overflow Design

Fig. 2 The cooling analysis of the original cooling channel design.

The result indicates heat accumulation in the middle area as well as the shaft.

10 Real-World Injection Molding Simulation Case Studies | 19

In order to improve the cooling time, they altered the cooling system that can better conform to the shape of the part
(Fig. 3). The cooling in the middle area as well as the shaft was completed and in addition to those areas, new
cooling was applied to the outer sides as well. After the design changes, Linear AMS used Moldex3D eDesign to
simulate the revised cooling design. The analysis results of the modified cooling channel design showed a much
more uniform temperature distribution (Fig. 4) compared to the original design.

Cooling follows Center area Cooling applied

part contour cooling in shaft

Fig. 3 The revised cooling channel design

Fig. 4 The analysis results of the revised cooling channel design.

The temperature distribution is much more uniform

As a result, Moldex3D has successfully reduced the cycle time from 112 seconds to 35 seconds. This allowed the
customer to produce a higher volume of parts without making additional molds and using additional presses.

10 Real-World Injection Molding Simulation Case Studies | 20

 Filling 5% Misc 15% Filling 5% Misc 15%
Cooling 71% Savings 69%
Packing 9%
Packing 9%

Cooling 2%

Conventional Cycle Conformal Cycle

Fig. 5 The breakdown of savings in this case: the reduction in the cooling
cycle has translated to 69% in the manufacture cost.

Results
The benefit of using Moldex3D is making it possible to present the time savings prediction to the customer. From their
experience with Moldex3D, Linear AMS has found that the cooling predictions are surprisingly accurate and they now
can confidently tell their customers how they can better help them reduce their cycle times (Fig. 6).

Fig. 6 The difference a savings of 77 seconds per shot can make over the course of a year

10 Real-World Injection Molding Simulation Case Studies | 21

TomTom Solved Deformation Issue of Navigation
System Parts through Moldex3D

Customer: TomTom Asia

Country: Taiwan
Industry: Electronics
Solution: Moldex3D eDesign, Fiber Module

TomTom is the world’s leading supplier of in-car location and

navigation products and services focused on providing the
world’s best navigation experience. TomTom’s products
include portable navigation devices, smart phone apps, GPS
sports watches, in-dash infotainment systems, fleet
management solutions, and maps and real-time services,
including the award winning TomTom HD Traffic. (Source:
http://www.tomtom.com )

Executive Summary
The product in this case is a front cover of the cradle of a
truck GPS navigation system. Deformation is a significant
issue that has to be controlled in order to conform to the
aesthetic and assembly requirements. In the original design,
the maximum deformed magnitude could reach 2.3mm
whereas the qualified value should have been less than
0.3mm. TomTom used Moldex3D to design several trial
methods and predict each warpage results. As a result, they
Image Courtesy of TomTom Asia were able to obtain the most effective design and meet the
specification.

10 Real-World Injection Molding Simulation Case Studies | 22

Challenges
　● The mold trials display a serious deformation issue
　● The gap exceeds the required spec. (≥0.3mm)

Fig. 1 The deformed situation of a real product showed 2.3mm which was over the spec. requirement.

Solutions
TomTom utilized Moldex3D eDesign to simulate the temperature, pressure drop and mechanical perspectives of
several improved designs and was able to find out the most optimized design.

Benefits
　● The assembly gap has been significantly reduced from 2.3mm to 0.25mm
　● Reduced mold-trial frequency by 3 times
　● Raised the yield rate from 55% to 92%
　● Reduced the cost by USD$20,000 and development time by 6 weeks

Case Study
The product in this case is the front cover of a cradle, and its main function is to lend support to the navigation device.
The objective of this case is to reduce serious warpage after molding. TomTom utilized Moldex3D eDesign to
simulate the molding scenario of the original design and observed obvious issues. In the original design, the front
cover is locked with the mating part and there is a 2.3mm gap which exceeds the spec. of 0.3mm. Fig.2 shows the
CAD model and its simulation result, in which serious warpage at the edge of the part can be observed. The dotted
line in Fig. 2 shows the deformed tendency. It will affect the assembly and cause shape defects that would have a
direct negative impact on the dimensional functionality and its physical appearance. Thus, in order to solve this
problem and produce high-quality products with fine aesthetic attributes, TomTom considered applying several
alternative revised designs.

Fig. 2 The CAD model of the original design (left) and its simulation result (right)

10 Real-World Injection Molding Simulation Case Studies | 23

Fig. 3 shows a large pressure drop and it is a critical factor that dominates deflection. Thus, the following study
mainly focuses on how to reduce this pressure drop. Apart from the pressure drop, uneven heat distribution is
another factor of deformation and will also be considered in the revised design.

Fig. 3 (Left) Original design of simulated sprue pressure results ;

(Right) Heat accumulation in the center region

TomTom considered three influential factors including thermal, mechanical and pressure drop to reduce warpage.
Table 1 shows the 6 design changes proposed by TomTom and the contributing factors they considered.

Considered
Revised
Factors Design Changes Targets
Design
of Warpage

Add cooling channels To increase the cooling efficiency and

Thermal factors Type A
in the hot area diminish mold temperature differentials

Add ribs in the weak To strengthen the weak region to maintain

Mechanical factors Type B
area the shape accuracy

Change the gate To improve flow balance and reduce the

Type C locations and pressure drop for a more uniform pressure
numbers distribution

To enhance the packing efficiency and melt

Increase the wall
Type D pressure of the penetration in order to
Pressure drop section by 0.3 mm
achieve uniform volumetric shrinkage
factors
To shorten the flow path to increase the
Reduce the length of
Type E packing efficiency and achieve uniform
the runner
volumetric shrinkage

Change the cold To reduce the length of runner (This

Type F
runners to hot runnersmechanism is the same as type E).

Table 1 The 6 design changes

10 Real-World Injection Molding Simulation Case Studies | 24

Table 2 is the summary of the pressure drop, warpage of the original and each revised design. As shown in the
results, Type C, D, E and F have a higher contribution on warpage reduction. Thus, TomTom combined these 4
design changes as the optimized design. Fig. 4 shows the comparison of the optimized design with the lowest
pressure, 31.25 MPa, and the minimum deviation with the CAD model.

Side Curve Warpage

Type Pressure Drop (MPa)
(%) Compared to CAD

Original 138.33 31

Type A 138.28 30

Type B 137.31 28.2

Type C 88.26 15.71

Type D 86.58 14.32

Type E 73.21 17.26

Type F 52.17 8.59

Table 2 Summary of pressure drop and warpage condition

Fig. 4 Optimized profile of deflection diagram

After the design modification, TomTom used Moldex3D eDesign to simulate both the original design and the
optimized design. The analysis results of the original product design showed obvious warpage. In the optimized
design, there is a qualified magnitude and significant improvement on warpage. Next, TomTom compared the
simulation results with the actual mold trial results and found a high correlation between both results. The original gap
is 2.3mm and the gap in the optimized design has been reduced to 0.25mm, which is a great improvement (Fig. 5).

10 Real-World Injection Molding Simulation Case Studies | 25

 Fig. 5 The photo of actual molded part in original and optimized gap

Results
Through Moldex3D’s analysis, TomTom clearly understood the deformed tendency and was able to predict the
potential manufacturing difficulties prior to actual production. In the end, TomTom was able to successfully solve
manufacturing issues and optimize the product and mold designs.

10 Real-World Injection Molding Simulation Case Studies | 26

FARPLAS Using Moldex3D to Overcome Difficult
Molding Issues in Multi-shot Injection Molding

Customer: FARPLAS A.S.

Country: Turkey
Industry: Automotive
Solution: Moldex3D eDesign, MCM Module

FARPLAS is a world leading auto manufacturer that operates

as a full-system supplier and determines to sustain the best
outcomes at the lowest costs. With more than 40 years of
experience, the spirit of an investor, global understanding,
and customer oriented approach, it has excelled in every field
it operates. (Source: http://www.farplas.com.tr)

Executive Summary
This study examines the filling analyses of PP+GF30 and
ethylene propylene diene monomer (EPDM), consecutively. It
is particularly difficult to work with this multi-shot injection
molding. Glass fiber must be oriented along the flow direction,
Image Courtesy of FARPLAS influencing the part deformation. If the distorted piece cannot
be fitted accurately while being inserted to the other
compartment, EPDM filling cannot be performed. Another
problem is the inability to fill a fine-layered EPDM onto
PP+GF30 in a full balanced manner. Several analyses on a
gasoline tank casing mold have been performed in Moldex3D.
The results help to foresee the potential issues and save time
for proper modifications accordingly.

10 Real-World Injection Molding Simulation Case Studies | 27

Challenges
　● Undesirable deformation after PP+GF30 filling
　● Correct gate locations and cross-section of the passage for EPDM filling
　● Sufficient EPDM filling amount to compensate the quantity and the interval of the hot runner as well

Solutions
Moldex3D can help to obtain correct design modifications, which result in smaller warpage in the first filling
(PP+GF30) and good filling behavior without short shot in the second filling (EPDM); its high mesh level option also
leads to closer results (nearly 100% accurate) between simulation and experiment.

Benefits
Product Quality Improvement:　
　● Reduce total displacement of PP+GF30 filling
　● Achieve short-shot-free EPDM filling
　● Obtain close-to-100% accuracy between simulation and experimental results of warpage and filling behavior
　● Save the required time to finish the design modifications as well as production cycle time and development costs

Case Study
The objective is to solve the problems in multi-shot injection molding of PP+GF30 and EPDM in which the warpage
resulted from the first filling (PP+GF30) should be minimized to a certain level to avoid any mismatch when the part is
inserted to the other compartment for the second filling, and the cavity of the second filling (EPDM) should be
properly designed to ensure a complete filling.

In this case, Moldex3D was first utilized before commencing the mold design of the first filling in order to initially
obtain the right design with acceptable part deformation. Then, the analysis of the second filling was carried out,
while the first mold design was underway. Finally, the mold design of the second filling referred to the modified one
after the short-shot problem had been overcome through the simulation analysis. Moldex3D detected the two critical
issues for this case: warpage problems from the first filling and incomplete filling from the second filling. The design
modifications for the cavity of the first filling comprised the addition of ribs at certain regions to support part rigidity
and the removal of some particular regions to promote more uniform wall thickness. (Fig. 1) As the supporting ribs
were added, the warpage from the first filling was reduced. (Fig. 2)

Fig. 1 Compared to the original design for the cavity of the first filling (left), the final design (right)
has more ribs, and some of its sections have been core out.

10 Real-World Injection Molding Simulation Case Studies | 28

 Fig. 2 The original design without supporting ribs (left) results in larger warpage total displacement
(max: 2.78 mm) than the modified design with supporting ribs (right) (max: 2.47 mm).

The design modifications for the cavity of the second filling comprised the geometry (Fig. 3) and the thickness (Fig.
4). Due to these changes, the EPDM filling behavior had been improved so that the filling could be completed without
any short shot. (Fig. 5)

Fig. 3 The geometry of the original design for the cavity of the second filling (left) has been modified
for its final design (right).

Fig. 4 The thickness of the EPDM passage in the final design (right) have been increased,
compared to the original design (left).

Fig. 5 The short shot problem for the original design (left) has been solved in the final design (right).

10 Real-World Injection Molding Simulation Case Studies | 29

The design revisions were verified by comparing their filling results with the results from their original designs in
which the improvements could be observed; the warpage had been minimized and the short shot had been solved.
Furthermore, the simulation results were also compared to the experimental results in which both simulation and
experiment were in a good agreement; the similarity was nearly 100% accurate when the mesh level for the
simulation analysis was changed from 3 to 5. One of the examples is the following short shot issue from EPDM filling
(Fig. 6 & Fig. 7):

Fig. 6 The short shot location of the original design in the simulation (left) is similar to the one
in the experiment (right).

Fig. 7 Both simulation (left) and experiment (right) result in short-short-free filling in the final design.

Results
Through Moldex3D analyses, both warpage of the first filling (PP+GF30) and filling behavior of the second filling
(EPDM) could be understood well. By providing the mesh level of 5 for the simulation model, the simulation results
could be nearly 100% accurate compared to the experimental results. These benefits could help to predict the
potential manufacturing difficulties prior to the actual production, so any necessary modifications could be made
beforehand, which in turn had savedalot of time for design improvements and development. As a result, FARPLAS
A.S. could successfully solve the critical manufacturing issues in this multi-shot injection molding.

10 Real-World Injection Molding Simulation Case Studies | 30

World’s Leading Automotive Part Supplier Utilizes
Moldex3D Analyses to Make Confident Decisions on
Product Design Optimization

Customer: Faurecia Interior Systems India Pvt. Ltd., Pune

Country: India
Industry: Automotive
Solution: Moldex3D eDesign

With 320 sites including 30 R&D centers in 34 countries around the

world, Faurecia is now a global leader in its four areas of business:
automotive seating, interior systems, automotive exteriors and
emissions control technologies. Faurecia is the world’s number one
supplier of seat frames and mechanisms, emissions control
technologies and vehicle interiors. The Group is also the world’s
third-largest supplier of complete seat systems and is Europe’s
leading name in automotive exteriors. Faurecia has one R&D center
and two production plants in Pune. (Source: http://www.faurecia.com/)

Executive Summary
This case features an important automotive interior part: a center
console fascia. Since it is a visible part, a high level of aesthetic
quality and appeal is required. Visible defects such as sink marks,
weld lines and flow marks should be controlled in less visible areas of
Image Courtesy of Faurecia Interior the part and kept at a minimum. Also, part warpage should be
Systems India Pvt. Ltd., Pune reduced in order to keep the dimensional precision within the gap
and flush tolerance to ensure a proper part assembly. However, it’s a
difficult challenge to fully control the warpage and eliminate the
defects merely based on the previously accumulated molding knowl-
edge and experience. Thus, Faurecia resorted to the help of
Moldex3D simulation solution to make confident decisions on part
and mold design optimization. Through Moldex3D detailed analyses,
they were able to look at a full spectrum of molding aspects, including
the detailed analyses on filling, packing, cooling and warpage and
examine possible solutions to resolve the critical product defects and
manufacturing difficulties. Ultimately, Faurecia was able to achieve
their goal and complete their project successfully.

10 Real-World Injection Molding Simulation Case Studies | 31

 Figure 1: This case features an important automotive interior part: a center console fascia.

Challenges
　● Avoiding visual defects such as sink marks, weld lines, and flow marks on the visible areas of the part
　● Reducing warpage within the gap and flush tolerance for part assembly
　● Controlling proper temperature and pressure to avoid over-packing and short filling

Solution
The goal of this project was to overcome the hurdles and challenges during the design and development phase
instead of at the later tool launch or the mold trial stage. In this case, the whole Moldex3D eDesign analyses
including filling, packing, cooling and warpage were utilized for a detailed study and design optimization.

Benefits
　● Successfully avoiding weld lines in visible areas
　● Drastically reducing part deflection to keep the gap and flush well maintained within the acceptable tolerance for
part assembly
　● Significantly reducing tool tuning cost by 68%
　● Successfully reducing what was traditionally a high scrap rate down to an unprecedented negligible number

Cast Study
In this case, Faurecia utilized Moldex3D eDesign full
package to get in-depth insights into what might
happen in the real molding with the original design.
Through Moldex3D simulation results, Faurecia
found out that with the original design, weld lines
would occur in the visible areas of the part and
warpage was severe enough to jeopardize the part
precision and it might cause a failed part assembly
later. Also, due to the drastic pressure and
temperature drop, over-packing was observed near
the gate area, and short filling was found in the thin
rib region. In order to solve the abovementioned
issues and produce a fine part of high aesthetic
appeal, Faurecia proposed a different feeding system
design along with a change in the part thickness to Figure 2: The original feeding system design:
tackle the problems. with one hot drop and one inverse sub-gate.

10 Real-World Injection Molding Simulation Case Studies | 32

 Figure 3: According to Moldex3D’s filling analysis, Figure 4: The circled area indicated a change
the weld-lines were observed in the visible areas of in the part thickness in th e revised design.
the part in the original design.

First of all, given the fact that the main goal of this project was to avoid/minimize all types visible defects like weld
lines, sink marks, flow marks etc., Faurecia suggested a thickness reduction in the fillets (Figure 4) to avoid corner
effects and other significant warpage in the Y & Z directions. In addition to making a change in the part thickness,
Faurecia revised the feeding system design. That is, to better control the pressure and temperature drop in the cavity,
Faurecia added one hot nozzle instead of injecting with only one single nozzle, then they added one more branch of
cold runner with submarine gates to make the flow more uniform. Injection ribs were also added in the part for
submarine gates to be placed (Figure 5). With the help of Moldex3D simulation results, the revised design proved to
be very effective in improving visible defects and showed positive results.

Feeding start
1st Valve gate Nozzle
1st Nozzle Gate

Sequential opening
2nd Valve Gate Nozzle
2nd Nozzle Gates

Figure 5: One more hot nozzle and one more branch of cold runner were
added in the revised feeding system design.

The following Moldex3D’s analysis results show a significant improvement in the weld line locations in the revised
design. The weld lines were successfully moved to the corners, the less visible areas of the part (Figure 6).

10 Real-World Injection Molding Simulation Case Studies | 33

 Figure 6: Two weld lines were moved to the corners and one weld line (upper right) was visible,
but would be covered by another part in the assembly.

Then, Faurecia conducted a correlation study between the simulation results and the actual injection trials in order to
observe the accuracy of simulation and see how their suggestions were working. Moldex3D’s filling and the filling
defect predications matched perfectly with the actual injection trials (Figure 7 & 8).

60% 85% 98% 100%

Trial

Simulation

Figure 7: Moldex3D filling prediction matched perfectly with the actual injection trial.

Visible Weld Lines

Trial Simulation Trial Simulation

Figure 8: The weld line occurred in the actual injection trial (left) and some changes
in gloss on the surface in the flow hesitation area were observed (right).

10 Real-World Injection Molding Simulation Case Studies | 34

According to the actual injection trial, Moldex3D’s warpage prediction was proven to be highly reliable. With the
revised design, the part deflection in the Y and Z directions were drastically reduced. Thus, the warpage was greatly
reduced to fit within the gap and flush tolerance to ensure a successful console assembly.

Trial Part CMM - Points Layout Simulation - Deflection Z - points 11 to 16

1 to 4 = Y gap with console

11 to 16 = Z gap

P11 P12 P13 P14 P15 P16

CMM 0.01 -0.47 -0.63 -0.68 -0.51 -0.23

Simulation Vz 0.35 -0.14 -0.18 -0.91 -0.16 +0.76

17 to 18 = X gap
Deviation 0.34 0.34 0.45 0.23 0.45 0.99

Figure 9: The CMM is done on painted part with Figure 10: The satisfactory warpage comparison
complete console assembly to check the gap between the simulation and the actual CMM trial
and flush. proved to be close to the reality.

Results
Through the accurate simulation results by Moldex3D, Faurecia was able make good use of the simulation data to
optimize the filling and packing profiles and successfully avoid the occurrence of weld lines in the visible areas of the
part. Also, the Y and Z deflections were drastically reduced, making the gap and flush well maintained for a
successful console assembly.

In addition, with the involvement of Moldex3D’s simulation results into the design and development phase, the tool
tuning cost, which normally contributed to at least 4% of the total tool cost, was able to significantly reduce down by
68%. Moreover, generally speaking, the scrap rate of the similar type of components was very high due to the strict
aspect requirements; however, for this part the scrap rate was greatly reduced to an unprecedented negligible
number. Each design change was simulated and validated by Moldex3D analysis, thus, Faurecia was able to make
confident decisions in every stage of the product development and optimization phase. That is, by optimizing the part
and feeding system designs, Faurecia was able to achieve these phenomenal results: prolonging the tool life,
lowering part rejection and successfully completing the project.

10 Real-World Injection Molding Simulation Case Studies | 35

Accurate Simulation Results on MuCell ® Technology
Enables Adoption of Moldex3D Solution

Customer: Proplast
Country: Italy
Industry: Research & Education
Solution: Moldex3D Advanced, Foam Injection Molding Module

Proplast was founded in Alessandria (Italy) in 1998 with the mission of

supporting enterprises in the plastics sector with a special focus on
applied research, technological innovation, recruitment of industry
talents, and training of human resources. In May 2008, Proplast opened
its new 3500 sqm premises which tripled the amount of space dedicated
to technical services for plastics sector entreprises. Proplast started its
activities with the support of four founding members (Bayer, Basell,
Guala and Mossi & Ghisolfi), and has hugely grown with the significant
support of other companies, associations, and universiteis involved in
the whole plastics chain over the years. (Source: http://www.proplast.it/)

This project was developed by Proplast in cooperation with Engel

Italia, Trexel and Onni-stamp.

Image Courtesy of Proplast

Executive Summary
Proplast’s goal in this project was to support their customers at every
stage of the MuCell® technology implementation. The support went
from part design and mold design to MuCell® molding trials and mold
piloting. Being that this is a challenging and complex process to
approach, Proplast resorted to the aid of Moldex3D solution for
MuCell® technology to help engineers navigate through the whole
process, optimize part and mold design, and successfully complete
the project achieving positive results at the end.

10 Real-World Injection Molding Simulation Case Studies | 36

Challenges
The greatest challenge in this case study was to accurately predict MuCell®, and make optimizations accordingly. In
this case, four particular areas were identified to further study the effects of MuCell® technology:

　● Sink marks
　● Warpage
　● Cells size prediction and validation
　● Cells density prediction and validation

Every step of the process was supported by using the simulation software, Moldex3D.

Specific features were added to the part design to further help evaluate, measure, and compare results

Solutions
Moldex3D simulation capabilities offer an opportunity to
simulate both conventional molding and MuCell® injection
molding. Basing upon software simulations, Proplast was
able to compare results of each process and better under-
stand operating differences between the two. Futhermore,
Proplast’s goal of conducting an in-depth analysis on the
microcelluar molding process, including cell dimension, cell
denisty and cell distribution was fulfilled through the use of
Moldex3D simulation technology.

Part Design

Benefits
Moldex3D provided an all-around simulation analysis on every aspect of the MuCell® process. With the valuable data
from the Moldex3D simulation, Proplast was able to gain insights into the MuCell® process, optimize part and mold
design, and most importantly offer constructive recommendations to guide their customers throughout the MuCell®
implementation. Moldex3D’s Foam Injection Molding simulation includes analysis on:

　● Process settings 　● Volumetric shrinkage / sink marks

　● Cycle time 　● Warpage / residual stress distribution
　● Pressure 　● Local cell size
　● Clamping force 　● Cell distribution and density
　● Expansion / weight reduction

10 Real-World Injection Molding Simulation Case Studies | 37

Case Study
Virtual foam injection molding is a great help in the whole process to predict MuCell® technology in order to
understand the real benefits MuCell® technology can bring. Moldex3D simulation enabled access to the following
important aspects of the MuCell® technology:

1. Sink marks:

Compact molding (left): Visible sink marks vs. MuCell® (right): No sink marks

The experiemental mold trial results proved that the simulation showed great accuracy of the sink mark prediction on
both the compact and MuCell® process. Also, from this example, it demonstrated clearly that the MuCell® technology
prevents sink marks very effectively.

2. Warpage:

Compact molding (left): Warpage is more severe than MuCell® (right)

Moldex3D successfully predicted the corner effect for both the compact part and the MuCell® part and at the same
time helped visualize the improvement on deformation using MuCell® before the part is actually injected.

Compact Molding MuCell®

Nominal Measurement Measurement Variation (%)
Simulation on real part Simulation on real part
A 100 108,76 109,17 109,22 109,16 -0.05

B 200 198,10 198,64 198,76 198,72 -0.02

C 200 198,61 198,92 199,18 198,86 -0.29

D 110 109,21 109,30 109,52 109,20 -0.29

Both simulation results and real part measurements showed great improvement on deformation using MuCell®

10 Real-World Injection Molding Simulation Case Studies | 38

3. Cells size prediction and validation:
The cell size prediction is crucial for MuCell® process, as the part quality and mechanical strength rely on the uniform
cell distribution and adequate cell size. Their correct prediction along the part is essential to make the design correct
prior to production. In this case study, the validation focused on three locations (as shown in the following pictures): 1.
Gating region, 2. Middle flow region, 3. End of flow region, in order to observe the cell growth along with the flow
length, and to validate the reliability of the software on the cell size prediction.

Location 1- Gating region: The cells remain small in size due to the high pressure near the gate location. The
simulation result provided good prediction of the cell size, validated by the SEM.

Location 2-Middle flow region: The cells grow as they go further from the gate; both simulation and SEM revealed
the same trend. The cells on the skin have less time to grow as compared to the core of the part, therefore the size is
smaller.

10 Real-World Injection Molding Simulation Case Studies | 39

Location 3- End of flow region: At the end of the flow area, the material has travelled the entire path which allows
the cell to grow; also, the pressure at the flow front is low and makes no constraints on the growth of the bubbles. It is
observed in both simulation and SEM validation, that the large cells are formed. Also, the cell sizes may vary in
different parts of this region.

4. Cells density prediction and validation:

In addition to the cell size, cell density is equally important for MuCell® process. The cell density and cell size are in
competition, when the average cell size grows along the flow length, it occupies a bigger area and inevitably the
density of the cell drops along the way. Here, the simulation results and SEM are shown for the comparison (as
shown in the following pictures).

Location 1- Gating region: The density is more difficult to be measured in SEM. By comparing the simulation
results and SEM, users are able to understand the relevance between the analysis and the experimental part in
density calculation. At the gate area, when the pressure is higher than the saturation pressure, the bubble is not
formed. While the bubble starts to grow in this area, the high pressure limits the cell size and allows the formation of
each individual bubble (cell nuclearation) without merging them into one big bubble. Here, the simulation and SEM
show the same results in this scenario.

10 Real-World Injection Molding Simulation Case Studies | 40

Location 2-Middle flow region: As the flow advances down the path, the cells also grow. When they grow bigger, a
given space contains fewer cells, resulting in lower cell density.

Location 3- End of flow region: At the end of flow area, the bubbles are much developed and merged together,
resulting in very low density with only a few cells visualized by SEM.

Results
In summary, through this case study, we could recognize that:

　● MuCell® technology is ideal for parts requiring minimized sink mark. Even when the part design is not
conventionally optimal (high thickness regions far from gate, high rib/wall ratio), sink marks can be eliminated.
　● MuCell® technology is able to significantly improve warpage in general.
　● In theory, the improvement on the quality is influenced by the cell growth along the part, which depends on
several factors, for example, the flow length and average thickness. In this case study we clearly see the cells
growth in regard to this factor.

Most importantly, all these key points mentioned above are able to be precisely simulated and predicted by Moldex3D
Foam Injection Molding simulation. With the help of Moldex3D, Proplast was capable of fully investiagting the
MuCell® process to identify the key benefits, and sucessfully assisted their customers with the implementation of the
MuCell® technology to achieve optimal surface quality.

10 Real-World Injection Molding Simulation Case Studies | 41

The Value of CAE Simulation
“The methodology of CAE analysis, which was developed and assessed at Proplast, accurately and reliably simulate
the MuCell® microcellular injection moulding process, and the quality and morphology of expansion. The flow
simulation of MuCell® components performed using Moldex3D provides optimised process parameters and global
molding quality (possible weight reduction, volumetric shrinkage, sink marks and warpage) as well as local
microstructural description of the cellular structure (size, density and distribution of cells). A good predictive
coherence has been observed regarding the here-mentioned study as far as process parameters, MuCell®
expansion, weight reduction ability and warpage are concerned,” said Andrea Romeo, CAE Manager at Proplast.

“The flow simulation of MuCell® components performed using Moldex3D provides optimised
process parameters and global molding quality as well as local microstructural description of
the cellular structure.”
- Andrea Romeo, CAE Manager at Proplast

10 Real-World Injection Molding Simulation Case Studies | 42

Attain Optimum Process Settings with Moldex3D DOE
Module to Improve Part Quality

Customer: Plazology
Country: UK
Industry: Consultancy
Solution: Moldex3D eDesign, Expert Module

Established in 2009 with the initial intention to supply injection mold

tools globally, Plazology has expanded its services due to customers’
requests. Plazology now take on full projects from part design to
production roll out. As an experienced and dynamic company,
Plazology strives to stay in touch with the latest technology within the
Plastics Industry, applying their knowledge and experiences (subject
to non-disclosure agreements) to the market/area of interest of our
customers. This enables Plazology to support numerous customers
to produce plastic components with high quality, good consistency
and cost efficiency. Over the years, Plazology has built up excellent
relationships with various organizations; this includes Universities
both in the UK and overseas. (Source: http://www.plazology.co.uk/)

This article is adapted from Injection World magazine, October

2014. ©Applied Market Information Ltd. 2014.
Image Courtesy of Plazology

Executive Summary
In order to produce good quality injection molded parts with high
consistency, a well-designed part and mold along with the right
material and processing parameters is critical. Changes made to any
of the mentioned four factors can have a significantly effect on the
molded part. Without having true understanding of the polymer
behavior inside the mold, more often than not, engineers tend to
“process the part dimensions in”. This leads to small processing
window – slight change in process can cause the part dimensions to
fall out of specification limit. The trial and error method is laborious,
expensive and ineffective, making it infeasible to be conducted in
today’s fast moving industry.

10 Real-World Injection Molding Simulation Case Studies | 43

Plazology, a leading company for injection molding technical consultancy based in United Kingdom, is seeing a big
push in molding simulation, which is able to predict how parts behaves inside the mold and post molded phenom-
enon. According to Jasmin Wong, Project Engineer at Plazology, “Traditionally, customers look to prototype molds
before commencing with large volume production molds. However, this adds cost and lead-time to the program,”
Jasmin points out. “Using simulation is an element where we can look to gain great confidence that the parts are
designed correctly for molding and the tools are designed with optimized cooling and gate positions.”

Plazology implemented Moldex3D because it helps them design faster with greater confidence. “Moldex3D has
provided us with additional confidence in our own internal decision making,“ Jasmin stresses. “Not only do we use
Moldex3D for full analysis work before building the actual tool, we can use it to troubleshoot current production quality
issues too. This has aided our customers’ toolmakers who don’t have easy access to molding simulation, helping
them to optimize their molds, cooling layouts and reducing cycle times.”

Challenges
　● Warpage
　● Concentricity

Solution
Use Moldex3D DOE module to determine the optimum process settings to improve warpage and linear shrinkage.

Cast Study
The following case study illustrates how Plazology utilizes Moldex3D plastic injection molding simulation software to
attain optimum process settings.

Figure 1. CAD model of a hand dispensing pump used in this case study

The above (Figure 1) is a hand dispensing pump of a sanitizer bottle. In this case study, the main area of concern for
this model is the warpage as well as the concentricity of the tube, as it affects the fit and functionality of the pump. As
the part has very tight tolerance, knowing the optimum process condition is required to keep warpage at the minimum
and concentricity as circular as possible.

Plazology first carried out a preliminary Fill, Pack, Cool and Warp analysis to ensure that the part has no filling
difficulty such as short shot or hesitation. DOE was then carried out. Since the area of concern is the warpage and
concentricity, these two will be the quality factor/response used in this DOE. Four control factors that will affect
warpage and concentricity will be used to carry out the DOE. In this case, melt temperature, packing pressure,
cooling time and fill time was used. Taguchi L9 DOE was then conducted. (Note: Taguchi DOE assumes no
significant interaction between factors which may not necessary be true. The reason why Taguchi was chosen in this
case study is to find out the relationship between the factors and response using shortened simulation time.)

10 Real-World Injection Molding Simulation Case Studies | 44

The Taguchi L9 DOE design can be seen in the Table 1.

No. Control Factor Level 1 (Low) Level 2 (Original) Level 3 (High)

1 Melt Temperature (°C) 225 235 245

2 Packing Pressure (MPa) 9 12 15

3 Cooling Time (sec) 8 10.6 12

4 Filling Time (sec) 0.1 0.2 0.3

Table 1. Taguchi L9 DOE design used in this case study

Table 2 shows the process setting of the 9 runs using Taguchi L9 Design. Moldex3D DOE then uses mathematical
calculations based on user’s specification (minimum warpage and linear shrinkage between nodes – used to
measure concentricity which will be explained later in the article) to determine the optimum process setting, reflected
as Run 10.

Run No. Melt Temperature (°C) Pack Pressure (MPa) Cool Time (sec) Fill Time (sec)
1 225 9 8 0.1

2 225 12 10.6 0.2

3 225 15 12 0.3

4 235 9 10.6 0.3

5 235 12 12 0.1

6 235 15 8 0.2

7 245 9 12 0.2

8 245 12 8 0.3

9 245 15 10.6 0.1

10 225 15 12 0.1

Note: Run 10 (optimized run) will be further explained under conclusion.

Table 2. Process setting of the Taguchi L9 runs

Warpage (Total displacement – mm)

From the 9 different runs, a main effect graph for warpage is plotted as seen in Figure 2.

Figure 2. Main effect plot for part warpage

10 Real-World Injection Molding Simulation Case Studies | 45

From Figure 2, it can tell that by increasing the pack pressure and cool time, warpage is reduced. Increasing melt
temperature on the other hand, leads to higher warpage. Using fill time of 0.2 sec or 0.3 seconds seems to have
slightly lesser warpage than 0.1 sec. Hence, we know that in order to achieve lower warpage, the optimum
process setting should be melt temperature – 225°C, pack pressure – 15MPa, cool time – 12 sec and fill time
–0.3 sec.

From the results obtained in Moldex3D, Plazology then make use of Minitab 17 (statistical software), to find out which
of the four factors has the biggest influence in the part warpage. Based on the table in Figure 3, cool time which is
ranked 1 has the biggest impact on part warpage, followed by pack pressure, melt temperature and lastly the fill time.

Figure 3. Response table for means (warpage)

The area graph seen in Figure 4 also shows a quick comparison of the 9 different runs against warpage. Run number
3 seems to give lesser warpage as compared to the rest of the 8 runs.

Figure 4. Area graph of part warpage (total displacement)

Concentricity (Linear shrinkage between nodes – %)

Concentricity is difficult to be measured, in real life or in
simulation. In real life, distance between different points is
measured using the coordinate-measuring machine (CMM).
In Moldex3D, the linear shrinkage between different nodes
is measured (see Figure 5 below). Eight different nodes
were identified. The linear shrinkage of the diameter of the
tube across A, B, C and D is measured. The lower the
linear shrinkage, the more circular or better concentricity
the tube of the part has.

Figure 5. Eight different nodes measured

for linear shrinkage

10 Real-World Injection Molding Simulation Case Studies | 46

The main effect plot for linear shrinkage can be seen below in Figure 6.

Figure 6. Main effect plot for linear shrinkage between nodes (measure of concentricity)

From Figure 6, it can be seen that in order to get better concentricity/linear shrinkage between the nodes, a lower
melting temperature, cooling time and filling time with a high pack pressure is preferable. Hence, we know that in
order to achieve lower linear shrinkage, the optimum process setting should be melt temperature – 225°C,
pack pressure – 15MPa, cool time – 8 sec and fill time – 0.1 sec. However, a cool time of 8 seconds might not be
practical since it will give high warpage (as seen in Figure 3).

Likewise, Minitab is used to find out which of the four factors gives the greatest impact on linear shrinkage. Based on
the table in Figure 7, pack pressure is ranked 1. This is followed by cool time, melt temperature and lastly the fill time.

Since 8 sec cool time will lead to high warpage, a compromise may sometimes have to be made. As mentioned
earlier, for linear shrinkage, pack pressure is more of a contributing factor than the cool time. Hence, it makes more
sense to use 12 sec cool time with 15MPa Pack pressure.

Figure 7. Response table for means (Linear shrinkage)

Comparing the 9 different runs for linear shrinkage (see Figure 8), run 6 gives lower linear shrinkage as compared to
the other 8 runs.

Figure 8. Area graph of linear shrinkage between nodes (measure of concentricity)

10 Real-World Injection Molding Simulation Case Studies | 47

Benefits
Based on user specification, Moldex3D uses mathematical calculations to obtain the optimized run (Run 10). For this
case study, weighting for warpage was the same as the linear shrinkage. However, based on the results above, the
optimum process setting for lowest warpage is to have cool time of 12 sec and fill time of 0.3 sec. Optimum process
for lowest linear shrinkage, on the other hand, requires a cooling time of 8 sec and fill time of 0.1 sec. Thus,
Moldex3D came out with a compromise process setting (melt temperature – 225°C, pack pressure – 15MPa, cool
time – 12 sec and fill time – 0.1 sec), which is used as the optimum run.

From the area graphs seen in Figure 9, it shows that Run 10 (optimized run), gives the lowest warpage compared to
the other 9 runs, while continue having low linear shrinkage.

Figure 9. Optimized run (Run 10) is compared with the other 9 runs.

From the DOE simulation results (see Figure 10 and 11), it tells that the part warpage and concentricity of the tube
has been significantly improved. Warpage is seen to have improved by approximately 20-30% while keeping a low
linear shrinkage to approximately 0.6-0.7%.

Before DOE

DOE Optimised Run #10

Figure 10. Improvement in warpage (total displacement) is observed

Figure 11. Improvement in warpage of the tube is also observed

10 Real-World Injection Molding Simulation Case Studies | 48

Based on the above case study, it is important that designers/molders understand that these numerical results in
simulation is a relative comparison and should not be treated as an absolute value. This is because there are various
uncontrollable factors in the actual mold floor which cannot be reenacted in simulation. However, with the aid of
Moldex3D DOE, it gives designers a head start on which are the control factors that should be focused on and the
relationship it has with part quality.

“We feel that Moldex3D has been fundamental in growing this side of our business due to the accurate and reliable
results it has shown to give Plazology,” Jasmin says. “Not only that, Moldex3D enables our customers to work better
and smarter with more confidence,” she adds.

About Jasmin Wong

Jasmin Wong is a Project Engineer for Plazology, based in UK. Plazology works alongside with various global leading
companies in the plastic industry, across Europe and Asia. They specialize in Product Design Optimization Injection
Mold Flow Simulation, Mold Design, Precision Mold Procurement and Management; and Mold and Process
Validation. Jasmin has also recently been awarded the Moldex3D Analyst Certificate by S4innovation, which supplies
Moldex3D software in the UK.

“ Moldex3D has provided us with additional confidence in our own internal decision
making. Not only do we use Moldex3D for full analysis work before building the actual
tool, we can use it to troubleshoot current production quality issues too.
We feel that Moldex3D has been fundamental in growing this side of our business due to
the accurate and reliable results it has shown to give Plazology.“

- Jasmin Wong, Project Engineer at Plazology

10 Real-World Injection Molding Simulation Case Studies | 49

 About Moldex3D

Moldex3D is the world leading CAE product for the plastic injection molding
industry. With the best-in-class analysis technology, Moldex3D can help you carry
out in-depth simulation of the widest range of injection molding processes and to
optimize product designs and manufacturability. In addition, its high compatibility
and adaptability have provided users with instant connection to mainstream CAD
systems, generating a flexible simulation-driven design platform.

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