Current Trends in Mold Filling Simulations: A Brief Explanation

Mold filling simulations are no longer to solve production problems; today, these simulations can be used on early design, verification, optimization of the part, mold development, and in design and manufacturing processes. Mold filling technology has seen clear growth and many recent advancements, and now more than ever it can help you improve your production.

Faster Modeling and Meshing

Before, analysts could be seen spending days on modeling and meshing alone before analyzing. Thankfully, with the creation of fully automatic eDesign and BLM mesh generators, meshing takes nothing more than one click; even better, the mesh can be updated simultaneously with part modification as well. Due to these changes, mold filling analysis no longer stays in the hands of the CAE analyst, but rather the mold designer (or the product designer at the upper stream). This analysis software helps designers accomplish many things: determine the position of sprue, balance the runner design, optimize the cooling channel deployment, and more. Also, working with a parallel computing cluster on a private cloud can help reduce computing time and response speed as well.

Emergence of Cloud Computing

CAE software suppliers now need to consider cloud computing when weighing options for the investment and deployment of next-generation computational resources. The recent introduction of internal cluster computing architecture is capable of corresponding to the requirements of macro memory and computing time of CAE computing.

There are plenty of examples of well-known CAE software already providing support to cluster computing; likewise, advancements in mold filling analysis software can now satisfy computing requirements of 10 million-level project by making the computer over ten times faster with the serial connection of multiple standard PCs. With this configuration on the cloud, numerous users’ computing requirements can be met immediately. Further, resources like flexible pay-per-use licenses can help users with less usage demand obtain the software and hardware they need.

Further Improvements and Advancements

Mold analysis covers a wide range of special processes, from injection compression molding to compression molding to metal injection molding. New technologies are capable of full support of FRP processes and integrating advanced molding technologies: these include gas-assisted injection molding, water-assisted injection molding, microcellular foam injection molding, and more. The most recent chemical foaming modules support polyurethane foaming process; with PU foaming simulation analysis, users gain a clear awareness of the manufacturing process, can accurately predict the dynamic behaviors during filling and foaming stages, refine the part design, and much, much more.

Further, In-Mold Decoration (IMD) injection molding continues to grow in popularity. Unfortunately, the molding processes still face a few challenges, such as proper ink wash-off, wrinkle deformation, and the like. Thus, the process can be both lengthy and costly, making it not as appealing as other options.

3D printing has also arisen in the realm of mold design. 3D metal printers are becoming more widespread and affordable every year, and when the process is integrated with traditional mold manufacturing, common problems such as heat power accumulation around the ribs and holes of larger molds can be mitigated. Even more, 3D conformal cooling cools all corners of the mold and drastically decreases overall cooling time while lessening warp and sink marks on the product surface. 3D printing, although not as widespread as other tools in the industry, offers a wide array of benefits and perks to its users.

With technological advancement and constant developments, the resources and trends in mold filling change almost on the daily. It can be hard to keep up with all the new concepts and the best software and hardware for your production. If you’re looking for a trusted partner with clear expertise and a variety of services, New Berlin Plastics is the right choice for you. New Berlin Plastics partners with OEMs and tiered suppliers to help them with engineering services and producing high-quality products. Contact New Berlin Plastics today for all of your manufacturing needs, from injection molding to design assistance to material management.