Reasons Of Why Should Do Moldflow Analysis

n mold making process, it's common to find mold flow analysis, but for more cost, why there are still many mold makers do it? Here is the reasons:

*No trial and error method - completely proven scientific engineering answers from art to part.

*Upfront decision making on plastics product design, material selection, right molding process selection (injection molding, insert, overmolding, gas assist, injection-compression, mucell, two shots), full optimization of tooling, and completely simulated manufacturing process.

*Complete optimization of product design – various material selection issues, right thickness, thick/thin issue, rib structure, structural concerns, weld line controls, residual or structural stress issues, product functional requirements, sink or appearance, gating locations, filling concerns, clamp tonnage or molding questions, and answers to many what if or will this work questions without any tooling/molding.

*Complete optimization of Injection Molds and Tooling – Select right gate locations, runner/manifold balancing and sizing, cavity layout, which injection mold material to use, prototype or production tooling, inserts or thermal pins or waterlines, optimization cooling layout, hot spot issues, oil heating or water cooling, complete engineering calculation of pressure or force for moving sliders, lifters, and core pulls, overall tooling stress/life cycle analysis, complete structural or thermal analysis for tool life, core pull or core deflection issues, clamp force or structural tooling issues, reasons of tool failure, post molding /tooling issues, and optimization of your mold design.

*Complete Injection Molding optimization – optimal gate location, balanced filling and packing, reduce or complete eliminate  molding issues of short shots, air trap, weld lines, jetting, flow lines/marks, gate blemish, shear heat, fiber breakage, surface finish, burns, flash, clamp tonnage, part weight, venting, over packing or under packing, race tracking, hesitation, part failures, functional or testing issues, quality issues, multi-cavity issues, overall process control or cycle time, right machine size, high pressure, dimensional stability, warpage issues, shrinkage issues, fiber orientation, material issues, flow leaders,  etc.

*Try different materials or different designs without building prototype parts or tools. Get virtual parts with simulation.

*Optimize your plastics parts for exact machine specification, cycle time, cooling, DOE, improve molding set ups, reduce clamp tonnage without taking your production time or putting any tools on molding machines- improve your bottom line profit.

*Optimize your overall cycle time. 10-30% reduction in cycle time on one part may as well pay for complete flow analysis of many molded parts.

*Make plastics product design optimization, design for manufacturability, robust engineering in product development cycle, and reduced engineering changes part of your upfront engineering and compete globally with advanced engineering that is unmatched…..

*Select the right source with expertise with practical experience in simulation, design, tooling, and molding (not experts in just running analysis or only does moldflow simulation for your project) otherwise you would be paying for analysis costs as well as for all tooling and molding issues and not realize any savings from all of these above benefits of upfront process simulation.

Any information or question on mold, contact Shine freely.