Moldex3D is used to simulate the complete injection molding process. It shows if and where any defects will occur and how the chosen material will behave during the whole process.

Plastics Injection Molding

Moldex3D uses it's the best-in-class analysis technology to provides the injection molding industry the most comprehensive set of tools to optimize product design and maneuverability, to shorten the time-to-market and therefore maximize profits.
The following are typical defects and problems that occur during the Injection molding process that can be predicted and therefore be prevented using Moldex3D:
Common injection molding that can be predicted and prevented using Moldex3D:
  • Short shot
  • Burning
  • Weldlines
  • Sink marks
  • Warpage
  • Flashing
Why use Moldex3D?
Why would you want to use Moldex3D?
  • Choose the best suited material, design, cooling setup and process conditions without interruption of the production line
  • Choose the best suited material, design, cooling setup and process conditions without interruption of the production line
  • Choose the best suited material, design, cooling setup and process conditions without interruption of the production line
  • Choose the best suited material, design, cooling setup and process conditions without interruption of the production line
Standard Injection Moulding Solutions

A) Filling

  • In Moldex3D, most potential problems are fixed during the simulation of the filling process. You can optimize the gate and runner design with minimum weld lines, air traps, burn marks, and short shot problems. Optimize the process conditions in the filling stage, such as injection time, melt temperature, etc.

B) Packing

  • Moldex3D can predict the gate freeze time and estimate the packing profile for the average pressure effect. Minimize sink marks and flash problems. During packing, you can predict the volumetric shrinkage and requirement of clamping force to minimize warpage control.

C) Cooling

  • Moldex3D supports cooling simulation with advanced analysis capabilities for mould and cooling circuit designs. This includes transient cooling, variotherm, conformal cooling, and 3D coolant CFD cooling simulations. You can control mould temperature variations to optimize cooling efficiency and minimize part warpage.

D) Warp

  • In the warpage process, Moldex3D allows you to validate part deformed ratio of shrinkage effect and identify warpage causes. You can evaluate fiber orientation, residual stress, and material viscoelasticity effects on warpage. Moldex3D provides flatness to evaluate the warpage of a surface plane and enhanced warp analysis to consider transient effects in the mould.

E) Multi-Component Moulding

  • In Moldex3D you can simulate insert moulding, over moulding, and multi-shot sequential moulding processes. Evaluate interactions of varied materials and consider the material properties to minimize the warpage and delamination. You can evaluate core deflection by unbalanced flow and detect potential re-melt issues.
Innovative Moulding Processes

A) Gas/Water-Assisted Injection Moulding (GAIM/WAIM)

  • Moldex3D provides 3D visualization of dynamic gas and fluid penetration. In Moldex3D you can determine polymer and gas entrance positions with proper injection time and injection volume of plastic and gas. The ability to optimize skin thickness and core-out ratio distribution to predict corner effect and blow though. Support push-back analysis in the full shot process to avoid the switchover mark and material waste.

B) Powder Injection Moulding (PIM)

  • Moldex3D provides freedom of shaping metal/ceramic parts. It can simulate the injection moulding stage in the process workflow. And you will be able to visualize the flow behaviour of feedstock. It provides a prediction of black lines due to phase separation of powder and binder.

C) Co-Injection Moulding (CoIM)

  • In this process, Moldex3D provides visualization of dynamic filling interactions of skin and core materials. It can optimize geometry thickness and process conditions based on blow-through prediction. It can identify temperature imbalance, and pressure resistance variations, and optimize shrinkage and warpage.

D) Bi-Injection Moulding (BiiM)

Moldex3D can define two independent melt entrances and process parameters for varied materials in this process. Visualize the two-melt front advancement and predict the potential weld lines to optimize gate design.

E) Compression Moulding (CM)

  • Moldex3D provides better control of the compression process. It allows for the control of the process variation after the compression to decide the charge design. Moldex3D can predict optimized compression conditions for the perfect shape of larger and intricate parts. It can simulate fiber length orientation to avoid degradation, bleeding, or flashing, and optimize product strength. Moldex3D can integrate with LS-Dyna for a more accurate compression moulding process from the solid deformation stage to the liquid filling stage.

F) Injection Compression Moulding (ICM)

  • A feature in Moldex3D provides enhanced replication for the parts with microstructures. Moldex3D can visualize property changes in the compression moulding process. Moldex3D provides support with VE and optics analysis for thin and flat products to optimize residual stress, shrinkage, and warpage.

G) Foam Injection Moulding (FIM)

  • In Moldex3D you can visualize the melt expansion behavior of polymer gas during the microcellular foaming process. Moldex3D also visualizes cell size and density distribution with consideration of cell nucleation and growth. There is an evaluation of the surface quality and bubble effect to reduce weight, tonnage, and shrinkage. Moldex3D has support for the core-back feature for a better understanding of gas volume fraction variation of cell distribution. For structural performance validation, Moldex3D provides cell size and density data output to Digimat.

H) Chemical Foaming Moulding (CFM)

  • In Moldex3D you can get bubble property validation under the chemical response. It can predict the bubble variation and density distribution under the chemical effects. It can also ensure a desired volume-to-weight ratio of the product.


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