Moldflow analysis is a computer-aided engineering tool that simulates how molten plastic flows through the mould. It predicts potential defects before any steel is cut, covering all the critical stages of injection moulding: filling, packing, cooling and warpage.
Two ways we offer it
A consultancy service open to any manufacturer, whether the part is new or already in production.
For a new project, we start by discussing your objectives, then carry out the analysis. Findings are presented in a live meeting, followed by a written summary report you can act on or pass to your toolmaker. The colour plots are in it as the supporting evidence.
For an existing job, typically troubleshooting, we replicate your current process to establish a benchmark, then work to determine the root cause of the problem. We feed back to you with our recommendations, which may be process change requirements or a part geometry change.
Most of the work is on new parts, but a good share of it is finding the cause of a problem somebody has been living with.
How the simulation works
- Fill. We simulate the plastic flow to identify pressure requirements, temperature mapping and fill pattern optimisation.
- Pack. Gate freeze-off, clamping force and sink mark prediction.
- Cool. Evaluate the cooling circuits and heat removal efficiency. Cooling accounts for up to 80% of an injection moulding cycle and is often overlooked.
- Warp. Assess shrinkage, crystallinity and the other factors affecting part distortion.
This scientific, iterative process means each phase of the moulding is optimised rather than left to chance.
Key benefits of Moldflow simulation
Our Moldflow analysis delivers numerous advantages to your manufacturing process.
- Time and cost savings. By identifying potential issues early in the design process, you avoid costly modifications and production delays.
- Precision engineering. Our injection moulding simulation software accurately predicts filling patterns, cooling efficiency, shrinkage and more.
- Optimised cooling efficiency. Cooling accounts for up to 80% of cycle time. Moldflow simulations make sure your cooling systems are optimised, improving both part quality and cycle times.
Applications of Moldflow analysis
Whether you are developing complex medical components or large-scale automotive parts, our mould flow analysis tools give you actionable data to optimise your products. We assist in:
- Tool design optimisation. Making sure your moulds are designed properly before any steel is cut.
- Product testing. Using injection moulding simulation to validate your product design, material choices and processing parameters.
- Defect elimination. Detecting issues like air traps, weld lines or undercuts before they affect production.
On parts we are not moulding
A good proportion of this work is for tools running elsewhere, including tools already in production. There is no obligation to move the job and no attempt to persuade you to. If the analysis shows the tool is sound and the process needs changing, that is what the report will say.
When to run it
Before the steel is cut. After that it becomes diagnosis rather than prevention, still useful, but more expensive to act on. The cheapest analysis is the one that changes a CAD model; the most expensive is the one that justifies a tool modification.