Moldex3D is excited to announce that along with our Mexican partner, Inteligencia Mecanica, we will be exhibiting at Expo Plasticos 2017 in Guadalajara, Mexico from March 28th to March 30th.

Being one the of most important trade fairs for plastic industry in Latin America market, Expo Plasticos has grown more than 30% over the course of past 4 years. It has become the meeting place for the industry and a consolidated event in which you will find the enterprises, the technologies and the solutions for the plastic industry in order to grow and flourish your business.

Moldex3D professionals will be on-site to demonstrate our simulation capabilities and show you how Moldex3D can help with your plastic part designs and manufacturing. Successful case studies will be shared to give your further insights into how the world’s leading companies are using Moldex3D to solve their plastic product design and manufacturing challenges.

Please come visit us at our booth #132 during the Show. You’re welcome to bring your product design questions or any inquires you may have to us and we’ll happy to discuss them with you in details. Every visitor will receive a special gift from us, free of charge!

*Spanish-speaking professionals will also be on-site to answer your questions and inquiries.

Venue

Expo Guadalajara
Av. Mariano Otero No. 1499
Col. Verde Valle, Guadalajara, Jalisco, México C.P. 44550

Contact

For any questions, please write to sales.us@moldex3d.com

Date | 2017/01/26

As the wire strands get smaller in diameter, ensuring the integrity of wire placement has become challenging during the IC packaging process. The common defects include wire sweep, wire breakage and wire cross-over. The common materials for wires are gold, copper, aluminum to name a few.

In order to ensure product quality and improve performance, multiple materials are used in manufacturing. Moldex3D supports wire sweep simulation with multiple wire material definitions.

Wire Material Setting

Step 1. In Moldex3D Mesh, users could create solid mesh for IC components and set up the wires. Then, check the Layers: the layer, SRMI$, is the solid model and WL$PF1 is the wire.

Step 2. Click  Wire Material Setting and follow the message in the command prompt.

After selecting the wire curves, press Enter. Users could name wire material group and assign the color of it.

Step 3. Export the model with mesh format. Then open Moldex3D Project and create a new project.

Step 4. Create a new simulation run and assign the material for each wire group. Next, open drop down window and click New to open Moldex3D Material Wizard. Pick the materials and right-click to Add to Project. After choosing all materials you need, close Material Wizard. Users could choose the materials in the drop down window one by one.

Step 5.  Check the model in the display window.

Date | 2017/01/26

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

Customer Profile

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/en-US/) 

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 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

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).

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).

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

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.

Designing and computing plastic parts, manufacturing prototypes and series – are common tasks for all participants in the plastics processing industry. Precondition for the success of a project is a precise and solution-focused communication between the partners involved. Take the opportunity to inform yourself in detail about all the novelties and possibilities.

Due to being so visual, simulation is the language that is understood by everyone. Simultaneously, it also promotes reliable data, information and knowledge and it manages to successfully implement latest developments in future-stable solutions.

As part of our user meeting we offer you the opportunity to show your experience gathered with Moldex3D to a high-caliber professional audience in form of a user presentation.

The conference languages will be German and English. Simultaneous translators allow you to easily understand the offered content.

Venue

Conference Centre Fortress Marienberg in Würzburg
Address: Oberer Burgweg, 97070 Würzburg, Germany

Contact

e-mail: events@simpatec.com
Tel: +49 241 565 28 28-86

This year, CoreTech System (Moldex3D) will be attending ATCx: OptiStruct Conference taking place on February 9, 2017 at the Altair Headquarters. This event will bring structural engineers and CAE engineers together to hear about the latest product updates on Optistruct 14.0, and learn from industry experts as they discuss the cutting edge simulation solutions to overcome real-world design and manufacturing challenges. Alex Baker from Moldex3D will talk about the tight integration between Moldex3D and OptiStruct to help engineers shorten the gap between actual production and structural analyses by mapping Moldex3D injection molding simulation results to structural analysis solver OptiStruct using Moldex3D FEA Interface.

Be sure to find us at the exhibitor area and attend Moldex3D’s presentation to explore a broad range of simulation solutions provided by Moldex3D to help you open up new potential for quality and efficiency! Register Now>>

Moldex3D Speaking Session

Date | 2017/02/03

Continuous fiber composites give great strength to plastic products. The most common manufacturing technique of strengthening the product structure is to use laminated fabric designs because the characteristics of these fabrics not only can meet the lightweight needs but also offers high strength to the products. In recent years, along with the demand of light-weight development, manufacturers have started using continuous fiber composites in different injection molding processes.

In one fabrication, the fiber-layered prepreg is added in the mold by thermoforming as an insert. Then, a back injection is performed to attach structural functional structures to the prepreg while maintaining lightweight properties. (Fig. 1)

Fig. 1 A composite sheet product made by thermoforming and back injection

The composites molding process mentioned above is called two-step over molding. It usually consists of:  1. draping process of a fiber prepreg  2. back injection. The shaping of a prepreg is done first by soaking a dry fiber fabric in the resin under room temperature, then put it under low temperature and freeze it into a fiber prepreg. Next, the solid and flake prepreg will be moved into the mold by robotic arms, and the draping process will proceed accordingly.

The main goal of draping process is to shape the laminated fiber mat. The fiber prepreg will be heated and soften through infrared radiation, and then be compressed and solidified. After the prepreg is shaped, plastic melt will be injected into the mold. The molded product will consist of two parts: 1. continuous fiber prepreg  2. plastic molded part. A major issue in this case is to effectively predict the product properties which combine these two parts.

Fig. 2 Two step over molding process

Source : Kauss Maffei, FiberForm lightweight parts The perfect combination of thermoforming and injection moldingmbination of thermoforming and injection molding

Moldex3D R14 version has integrated with LS-DYNA’s draping analysis to simulate the deformation behavior. The fiber mat orientation of the fiber prepreg after the draping process can be considered in Moldex3D’s analysis for the subsequent molding process to obtain a more comprehensive warpage analysis of the composites product. LS-DYNA focuses on analyzing the deformation behavior of a continuous fiber in compression molding. Moldex3D will incorporate LS- DYNA’s calculation of prepreg deformation and consider the product geometry and continuous fiber mat orientation analysis as the parameters of a part insert. In Moldex3D’s filling analysis, it will consider the prepreg geometry and its material characteristics as the boundary conditions and in the subsequent warpage analysis, it will consider the insert as a continuous fiber composite material and perform a deformation analysis of a multi-component part (Fig. 3).

Fig. 3 Integrated analysis for two steps over molding process between Moldex3D and LS-DYNA

Fig. 4 is a Moldex3D’s case study example. The plastic structure part is molded on top of the fiber prepreg; Moldex3D is used to conduct the filling, packing and then the warpage analyses with the consideration of continuous fiber mat orientation.

Fig. 4 Different geometries for two steps over molding process

Through Moldex3D’s Multiple Component Molding feature, the fiber mat orientation predictions of a uniaxial prepreg in 3 different directions can be analyzed and the product’s strength variations of different directions can be attained. As shown in the analysis results, the deformation in the Z axis is the largest when the fiber mat orientation is at the angle of 45°. The least deformation occurs when the fiber mat orientations are at 0° and 90° with the deformation at 90° being the most ideal.

Fig. 5 The warpage predictions for different fiber mat orientations of prepregs

Moldex3D’s filling analysis considers the effect of chopped fiber orientation in the subsequent plastic molding process and is able to observe the influences of the plastic material and the chopped fiber orientation. In this case, the influence of the plastic material to the warpage is more significant; it causes greater shrinkage in the Y direction. When the fiber mat orientation is at 90°, the shrinkage can be compensated, making it the least deformed design.

Fig. 6 Moldex3D can predict the warpage behavior of the injected structure part

With this case, we can understand both the continuous fiber prepreg orientation and non-isotropic chopped fiber in two-step over molding will affect the product warpage. Furthermore, we find that fiber mat orientation is the main contributing factor of the product warpage. Moldex3D’s analysis provides great insights for its users in the planning of two-step over molding process and helps avoid excessive warpage to ensure the success of their composite products and assist users in maximizing their advantages.

Webinar: Understanding the Influence of Fiber on Structural Analysis

Structural integrity is one of the key concerns for many plastics part developers. This webinar will introduce the procedure and application by using Moldex3D’s simulation output for structural FEA analysis considering certain variables of molding process, such as fiber orientation or residual stress, and import them into the structural analysis software. Therefore, users can further evaluate advanced structural strength and impact property more accurately.

Registration

We’re offering two sessions for this webinar, so be sure to attend the one that best fits your schedule! Calculate your time zone by clicking here.

Moldex3D is pleased to announce that we will be returning to INTERMOLD KOREA 2017, Asia’s leading die and mold exhibition and the largest industry event in Korea. Held together with KOPLAS and HARFKO, INTERMOLD KOREA is the best venue to witness advanced technologies and equipment from around the world.

This year at INTERMOLD KOREA 2017, Moldex3D will demonstrate our latest CAE simulation technologies and showcase current and future industry trends. We cordially invite you to visit our Booth M419 and find out the best solution for you to overcome your daily plastic product design challenges!

Venue

KINTEX Center, Seoul, Korea

Contact

Vera Yeh
verayeh@moldex3d.com
+886-3-5600199 ext. 707

Moldex3D is delighted to announce this year we are having our FY’17 EMEA Channel Partner Meeting in Europe! This meeting will take place on 19-20 April at NH Hotel Utrecht in the Netherlands and it’s designed to meet all your needs. In this year’s event, you will:

• Uncover the key features and sales points of Moldex3D R15 and get geared up for the future product roadmap.
• Meet our Team and exchange valuable experience with other Regional Partners from Europe, Middle East, and Africa.
• Learn about the product highlights and sales techniques tailored to reflect the European market.
• Get the latest competitor analysis and practical real-world strategies to tackle the competition challenges.

It would be a great pleasure for us to meet you all partners in one meeting and we look forward to seeing you soon in Utrecht!

Detailed agenda coming soon!

Venue

NH Hotel Utrecht
Jaarbeursplein, 24,
3521AR
Utrecht – The Netherlands

Webinar: What’s New in Moldex3D R15.0

Simulation can help you make quick and informed decisions in the early design phase. But problem is, simulation preprocessing is all too often time consuming and laborious. Moldex3D R15.0 offers enhanced performance, accuracy and better usability to streamline simulation workflow and provide faster turnaround times with added efficiency. Join us for this live webinar to learn about the best and newest features/enhancements in Moldex3D R15.0 that can enhance your next simulation projects and results, saving you significant time and effort.

Registration

We’re offering two sessions for this webinar, so be sure to attend the one that best fits your schedule! Calculate your time zone by clicking here.

Moldex3D Users’ Meeting- North America 2017 is an annual event opportunity to strengthen the collaboration between Moldex3D Company and the plastic engineering community in North America region. This meeting will be the biggest event that brings together our top management, users, partners, and as well as experienced professionals working in the plastic engineering field under one roof to discuss the latest industry trends and know-how, and exchange valuable experiences to help bring your product to life.

The scope of this meeting will include:

• New product updates on Moldex3D’s latest version, Moldex3D R15
• Novel molding and plastic product design knowledge & technologies
• Moldex3D’s customer’s successful case presentations
• Interactive dialogue to shape the future developments of Moldex3D software
• Demonstrations on Moldex3D’s new simulation capabilities
• Plenty of networking opportunities with like-minded professionals

Stay tuned for more details of the event including event agenda, speaker lineup, etc.

Venue

TBD

Contact

Kiki Kratzer
248-946-4570 ext. 327
kikikratzer@us.moldex3d.com

Registration

[contact-form-7]

Moldex3D Users’ Meeting- North America 2017 is an annual event opportunity to strengthen the collaboration between Moldex3D Company and the plastic engineering community in North America region. This meeting will be the biggest event that brings together our top management, users, partners, and as well as experienced professionals working in the plastic engineering field under one roof to discuss the latest industry trends and know-how, and exchange valuable experiences to help bring your product to life.

The scope of this meeting will include:

• New product updates on Moldex3D’s latest version, Moldex3D R15
• Novel molding and plastic product design knowledge & technologies
• Moldex3D’s customer’s successful case presentations
• Interactive dialogue to shape the future developments of Moldex3D software
• Demonstrations on Moldex3D’s new simulation capabilities
• Plenty of networking opportunities with like-minded professionals

Stay tuned for more details of the event including event agenda, speaker lineup, etc.

Venue

The Inn at St. John’s
44045 Five Mile Rd., Plymouth, MI 48170
Click here for a map.

Please note that the Day 1 sessions of the conference will take place in the Grande Ballroom of The Inn at St. John’s, and parking is available by that side (see floor plan). The Day 2 sessions will take place at the Galilee Ballroom. Attendees may park in the front.

Contact

Kiki Kratzer
248-946-4570 ext. 327
kikikratzer@us.moldex3d.com

Registration

[contact-form-7]

Hsinchu, Taiwan – March 8, 2017 –CoreTech System (Moldex3D), the global leading provider of plastic injection molding simulation solutions, today introduced the latest release of Moldex3D R15.0. This newest version offers enhanced performance, accuracy and efficiency to streamline simulation workflow and provide faster turnaround times.

Reducing Pre-processing Time & Effort
One of the most significant improvements in Moldex3D R15.0 is the reduction in pre-processing time and effort. The new runner meshing technology enables automatic generation of high-resolution hexahedral meshes and offers various node types for line runner connections to better capture the intended geometric shape of the runner design and deliver more accurate predictions.

Also, the extended non-matching mesh technology supports the automatic meshing of mold components to be non-matched, such as the interface between part and part insert/mold base in order to obtain accurate simulation results with minimal effort.

Streamlining Simulation Workflow in One Integrated Platform
Moldex3D Studio is a fully integrated platform that streamlines all phases of the simulation workflow, from pre-processing to post-processing onto one intuitive, ribbon-style interface. The new platform complements the current Moldex3D Designer and Moldex3D Project applications and enables users to display and compare simulation results of multiple designs simultaneously to shorten the product development time.

Obtaining Optimal Accuracy through Fully Coupled Process Simulation
The fully coupled process simulation is a pioneering breakthrough in Moldex3D R15.0. Users can now take advantage of the new coupling technology which can simultaneously utilize Flow/Pack/Cool/Warp solvers to obtain optimal accuracy for simulating products of complex geometric designs or advanced manufacturing process like Rapid Heat Cycle Molding (RHCM).

Simulating New Process Applications
Moldex3D R15.0 also provides new simulation capabilities for In-mold Decoration (IMD) and Polyurethane (PU) chemical foaming process. The boundary condition application in the pre-processor of In-mold Decoration (IMD) simulation is made available the first time in commercial mold-filling analysis software to provide a quick and easy approach to meshing the decoration layers for simulation. Moreover, the “wash-out Index” feature enables designers to better predict washout of the ink of the decoration film to ensure successful decorative products.

The new addition of polyurethane (PU) foaming simulation supplements Moldex3D’s capabilities for chemical foaming processes; In addition to the existing microcellular foaming analysis for thermoplastics, PU foaming simulation provides part designers an ability to check the density distribution and ensure a desirable volume-to-weight ratio of the final part.

In addition, the enhancements in compression molding analysis enable a more accurate simulation for SMC materials, going from solid to molten and back to solid state, through a tighter integration between Moldex3D and LS-DYNA.

Bridging the Gap between Simulation & Shop Floor
The machine interface are further expanded to include over 15 mainstream injection molding machine manufacturers to shorten the gap between the predicted and real-life parameters.

Managing the Big Data for Effective Simulations
The new Intelligent Simulation Lifecycle Management (iSLM) solution provides an effective management of vast volumes of simulation data, giving teams at different geographic locations within an organization one single point of entry to store, share, and re-use simulation data in a safe and centralized environment.

“Moldex3D is devoted to improving its software’s functionality and simulation accuracy in each release,” said David Hsu, President of Product Development at Moldex3D. “With the new features and enhancements in Moldex3D R15.0, we aim to provide a high-performing CAE analysis with greater accuracy and efficiency to help users design and manufacture high-quality plastic parts with faster turnaround times which truly gives them an ability to keep an edge over competition and achieve excellent results.”

Moldex3D R15.0 is available now. For pricing and detailed product features, please contact your local resellers or sales representatives. Further information about Moldex3D R15.0 also can be found on the Moldex3D R15.0 Launch Page.

About CoreTech System (Moldex3D)
CoreTech System Co., Ltd. (Moldex3D) has been providing the professional CAE analysis solution “Moldex” series for the plastic injection molding industry since 1995, and the current product “Moldex3D” is marketed worldwide. Committed to providing advanced technologies and solutions to meet industrial demands, CoreTech System has extended its sales and service network to provide local, immediate, and professional service. CoreTech System presents innovative technology, which helps customers troubleshoot from product design to development, optimize design patterns, shorten time-to-market, and maximize product return on investment (ROI). More information can be found at www.moldex3d.com.

WORKSHOP ที่จะทำให้่คุณใช้โปรแกรม CAE เป็นภายใน 1 วัน เพื่อกำจัดตรวจสอบปัญหาเหล่านี้ในแม่พิมพ์

1. SHORT SHOT ปัญหาฉีดไม่เต็ม
2. WELDLINE ปัญหารอยเชื่อมประสาน
3. UNBALACE FLOW ปัญหาการไหลที่ไม่สมดุล
4. SINK MARK ปัญหายุบของชิ้นงาน

การสัมมนาเชิงให้คำปรึกษาในครั้งนี้มีความมุ่งหมายเพื่อที่ให้ ผู้เข้าร่วมอบรมสามารถ

1. ผู้เข้าร่วม workshop เข้าใจหลักการการใช้งานและขั้นตอน software ประเภท CAE ที่เหมาะสม
2. ผู้เข้าร่วม workshop สามารถอ่านผลของโปรแกรมและสรุป เพื่อค้นหา
   ปัญหาฉีดไม่เต็ม ปัญหารอยเชื่อมประสาน ปัญหาการไหลที่ไม่สมดุล ปัญหาการเปลี่ยนแปลงของความดัน
3. สามารถนำ Software กลับไปใช้งานได้อย่างมีประสิทธิภาพที่บริษัทและใช้เป็นแนวทางแก้ปัญหาได้

กำหนดการ

วิทยากร

Mr. Paul Tsai และ เจ้าหน้าที่จาก Moldex Thailand
โดยคุณ Paul Tsai ซึ่ง มีประสบการณ์เชี่ยวชาญกว่า 30 ปี อยู่ในวงการอุตสาหกรรม
การผลิตรถยนต์ มีความเชี่ยวชาญเฉพาะด้านครอบคลุมทางด้านผลิตภัณฑ์พลาสติก
ออกแบบแม่พิมพ์ และการเพิ่มประสิทธิภาพการผลิต

จำนวนผู้เข้าอบรม
จำนวนผู้เข้าอบรม 5 ท่าน

Location

โมลด์เด๊กซ์ทรีดี สำนักงานใหญ่ ตึกเมืองไทยภัทรประกันภัย
252/124 ยูนิต (จี) ชั้น 26 อาคารเมืองไทย-ภัทรคอมเพล็กซ์ อาคาร 2
ถ.รัชดาภิเษก แขวงห้วยขวาง เขตห้วยขวาง กรุงเทพมหานคร 10310

Contact

รายละเอียดเพิ่มเติม ติดต่อ คุณเอกภัทร์ สุธาอรรถ
โทร 083-709-3928
Email : akekapat@saeilo.co.th
เบอร์แฟ็กซ์ 02-061-5570

Registration

[contact-form-7]

Moldex3D is pleased to announce that along with our local partner, PawForm, we will be exhibiting at INNOFORM 2017 in Bydgoszcz, Poland from 25th to 27th in April.

INNOFORM 2017 will be an excellent business platform and a place where manufacturers, distributors and scientists can exchange knowledge and experience with professionals in related fields. Moldex3D cordially invites you to visit us at our Booth #21 in Hall 2 to discuss the latest injection molding simulation technologies and explore the possible solutions to your plastic product design challenges.

Venue

Bydgoszcz Trade and Exhibition Centre
Gdanska 187 Str. 85-684 Bydgoszcz, Poland

Contact

Vera Yeh
verayeh@moldex3d.com
+886-3-5600199 ext. 707

Moldex3D together with our local partner CSoft is pleased to introduce our Molding Innovation Day at Holiday Inn Moscow – Sokolniki in Moscow on 25^th April, 2017. Technical presentations and discussion on the most up-to-date injection molding simulation applications will be the main focus of this seminar. Also, Moldex3D Regional Manager, Vincent Hung will be our highlight speaker to showcase the new powerful features of Moldex3D’s latest R15 version, helping you gain valuable insights and revolutionize your productivity. Make sure you book the date!

Agenda

Venue

Holiday Inn Moscow – Sokolniki
Rusakovskaya Ulitsa 24, Moscow, 107014 Russia

Contact

• Igor Barvinsky
  Tel. + 7 495 913 22 22 ext. 2264
  E-mail: ibarvinsky@csoft.ru

• Vera Yeh
  E-mail: verayeh@moldex3d.com
  +886-3-5600199 ext. 707

The post Molding Innovation Day 2017- CSoft, Moscow appeared first on Moldex3D :: Plastic Injection Molding Simulation Software.

Date | 2017/03/23

Multi-cavity co-injection molding is one of the most commonly used processes to manufacture automotive components and structural reinforcement products, and it has been widely applied in many industries. The benefits of multi-cavity co-injection molding include the ability to reduce material waste and cost, and further enhance the productivity of co-injection molding parts.

However, the same general guidelines for developing a single-cavity co-injection mold cannot be fully applied in the development of a multi-cavity co-injection mold. The key to a successful multi-cavity co-injection mold is proper core/skin distribution. The co-injection molding is already a complex process itself. By combining multi-cavity molding process, which often results in flow imbalance, it would be very difficult to achieve the desired distribution of materials.

Moldex3D, a computer-aided engineering tool, is often used to predict potential molding issues and analyze the intricate mechanism of multi-cavity co-injection molding system. The following case study illustrates how Moldex3D is used to evaluate the effects of injection flow rate and cavity design for designing a better multi-cavity co-injection mold.

The runner geometries and the cavity used in this multi-cavity co-injection simulation experiment are shown in Fig. 1. The material of the core and skin is POLYREX®PG-22. In the molding process, a certain percentage of skin is injected first, and then the core material is injected to finish the filling process. The skin to core ratio is 72:28.

Fig. 1 The cavity and the runner geometries used in the multi-cavity co-injection molding experiment

The comparison of the simulation and experimental results of the core layer melt front is shown in Fig. 2 according to the study. As shown, at a low injection flow rate (10.2 cm3/S), Branch 1 has the longest core penetration distance, while at a higher injection flow rate (51 cm3/s), Branch 2 is the longest. Both simulation and experimental results show similar trends.

Fig. 2 The blue lines show the melt front result measured in the experiments, and the colored red area is the melt front simulation result.

The following experiment was designed to further investigate the effects of different injection flow rates on the low-viscosity core material penetration. As shown in the analysis results, when the injection flow rate is at 10 cm3/S, the core material in Branch 1 reaches the cavity first. When the injection flow rate increases to 16 cm3/S, the core material in Branch 2 reaches the cavity first. Moreover, as the injection flow rate further increases, the proportion of the core material in Branch 1 decreases. The reason is that more core materials flow into the second and third cavities due to the high shear stress.

Fig. 3 Simulation results of different injection flow rates

However, the core material penetration simulation results cannot guarantee ideal skin/core distribution can be achieved in the final molded part. Fig. 4 shows unbalanced skin/core distribution in each cavity, regardless of high or low flow rate, since the first cavity has been filled at the earlier stage.

Fig. 4 The melt front simulation results of core material: (a) 81% filling; (b) 100% filling

Thus, in order to efficiently manage the skin/core distribution of the final molded part, it is necessary to take the effects of mold design into consideration. As shown in Fig. 5, if we modify the angles of the runners to a more symmetrical design, we can obtain a more uniform skin/core distribution (Model 2). If the runner design cannot be modified, we can modify the cavity design. Adding an overflow region or adding a connector between each cavity can both improve flow imbalance (as shown in Fig. 3).

Fig. 5 The influence of different mold design

In summary, the dynamic behavior of core material penetration in multi-cavity co-injection molding is a complicated issue, involving many factors such as flow rate, material properties and mold design. Influenced by the interactions between these factors, it is difficult to achieve a uniform distribution by simply changing the process condition parameters. Therefore, utilizing Moldex3D as a CAE tool has become a much more efficient way to quickly identify and fix potential issues prior to manufacturing and it can also benefit the development of multi-cavity co-injection molding technology.

Reference:

1. Wikimedia Commons, Website information: http://commons.wikimedia.org/wiki/File:Co-injection_(sandwich)_molded_part.jpg, Accessed: Nov. 25, 2014.
2. Yang, W.M., and Yokoi, H., “Visual analysis of the flow behavior of core material in a fork portion of plastic sandwich injection moulding”, Polymer Testing, 22, pp 37-43 (2003).
3. Job, S., “Recycling composites commercially”, Reinforced Plastics, pp, 32-38, Sep/Oct. 2014.
4. Pimenta, S., and Pinho, S. T., “Recycling carbon fibre reinforced polymers for structural applications: Technology review and market outlook”, Waste management, 31, pp 378-392 (2011).
5. Jackie Yang, Chao-Tsai (CT) Huang, Hsien-Sen Chiu, Jimmy C.Chien, and Anthony Wen-Hsien Yang, “Dynamic Behavior of Core-material Penetration in Multi-Cavity Co-Injection Molding”, SPE ANTEC Tech. Paper, Paper No. 2096345, 1-5 (2015).

The post Utilizing CAE Tools to Overcome the Challenges of Multi-cavity Co-injection Molding appeared first on Moldex3D :: Plastic Injection Molding Simulation Software.

Date | 2017/03/23

The draping process will change the fiber orientation of the orthotropic prepreg, and further affect its mechanical property and warpage behavior. Modex3D Multi-component module (MCM) module supports orthotropic material setting of part inserts and allows users to consider the effect of the previous shot. Applying project method or existing orthotropic material data, the mechanical property affected by the orientation of continuous fiber in the prepreg can be considered in details in the simulation.

Step 1.  To assign orthotropic material of the part insert, go to MCM tab in Computation Parameter of the MCM project. Under the tab, click Settings under Orthotropic Material Properties to launch the workspace and assign or modify the orthotropic material property. The option, User-defined properties will show up if any orthotropic material has been assigned.

Step 2.  In the workspace, users can create orthotropic material data to part insert. Click  Create property and select the target part insert mesh, and specify the property name and two directions of principle axis. By expanding the dialog, users can modify mechanical and expansion parameters in each axis direction.
Note: The principle axis is the two main orientations of the part insert material before prepreg.

• To import orthotropic material data, click  Import property, select target material data, and select a part insert mesh to assign it.
• To delete orthotropic material data, click  Delete property and select a property item to remove it.
• To re-assign orthotropic material to different part insert, right click property item and click Modify part insert, and select a different part insert mesh.
• To modify orthotropic material properties, right click property item and click Edit property.

Step 3. Click  to go back to Project. User-defined properties will be checked. Then, click OK to finish the settings and run analysis.

Step 4. For two-shot molding, users can use the same orthotropic material setting on the same prepreg insert for the second shot. Under MCM tab in Computation Parameter, check Link with previous shot and specify the project and run number as the resource of part insert data from the previous shot.

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Predict the warpage behavior of an orthotropic material in injection-molded polymer parts.

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Two-shot molding warpage analysis result

Link with the previous shot		No link with the previous shot

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Webinar: How Injection Molding Simulation Helps Reduce Warp Issues

Among so many challenges plastic injection molding molders and moldmaker face, warpage may be one of the greatest. The most frequently asked question is “What caused my parts warp?”

In this webinar, we will demonstrate how Moldex3D’s simulation tools can be used to help users better understand and investigate various plastic processing variables that can lead to warping, and eventually determine which one of them has the most significant effect on the parts. With Moldex3D’s True 3D warpage analysis, molders can take immediate corrective action before production begins without wasting time and effort on tryouts.

Webinar Highlights

• Introduction to factors affecting shrinkage and warpage
  – Geometry
  – Mold design
  – Processing
  – Material selection
  …and so on
• Moldex3D simulation capabilities for predicting and solving warpage
• Introduction to 3D volume shrinkage compensation method
• Real case studies

Registration

We’re offering two sessions for this webinar, so be sure to attend the one that best fits your schedule! Calculate your time zone by clicking here.

The post Webinar: How Injection Molding Simulation Helps Reduce Warp Issues appeared first on Moldex3D :: Plastic Injection Molding Simulation Software.

Connect Classroom Theory with Real World Solutions
~Visit Moldex3D at Booth 319 to find out the right molding simulation technologies to meet your specific needs~

CoreTech System (Moldex3D) is proud to announce that we will participate in ANTEC® 2017 at Hilton Anaheim in Anaheim, from May 8th to May 10th. Our Booth number is #319. We will not only showcase our newest simulation capabilities at the show floor, but also present our latest research studies in “virtual molding” technologies at this year’s event.

The followings are the topics we are going to present at this year’s ANTEC Conference:

Injection Molding Session: Simulation I

• May 8th, Monday Morning (08:30 – 09:00 AM)
• Ink-wash and Warpage Defect Prediction from the in-mold decoration Process Simulation
• Author: Tober Sun, CoreTech System Co. Ltd

Composites Session: Composite Modeling / Analysis

• May 8th, Monday Morning (10:00 -10:30 AM)
• Optimizing Process Condition of Resin Transfer Molding (RTM): Determining Material Properties for Numerical Simulation
• Author: Joe Wang, CoreTech System Co. Ltd

Engineering Properties and Structure: Polymeric Modeling

• May 8th, Monday Afternoon (4:00 – 4:30 PM)
• Long Fiber Orientation and Structural Analysis Using Moldex3D, Digimat and ABAQUS Simulations
• Author: Ivor Tseng, CoreTech System Co. Ltd.

Injection Molding Seminar: Simulation/Processing

• May 10th, Wednesday Morning (09:30-10:00 AM)
• Predict and Solve Stress Mark on Product Cosmetic Surface Using Controlled Sequential Valve Gating Simulation
• Author: Edward Wu, CoreTech System Co. Ltd

View the final ANTEC presentation schedule, please go to: https://www.eiseverywhere.com/ehome/184555/512992/

We cordially invite you to come visit us at our booth (#319) or attend our presentations to find out the right molding technologies for your needs!

For more questions, please contact mkt@moldex3d.com.

About ANTEC:
ANTEC®, produced by the Society of Plastics Engineers, is the largest, most respected and well known technical conference in the plastics industry.
For over 70 years ANTEC® has successfully expanded from the U.S. into Europe, India and the Middle each with further expansion to global locations in the coming years.
Each event boasts technical and business presentations on new and updated technologies, panels and tutorials, networking events and student functions – all providing attendees with face-to-face interaction with expert representatives from the largest industry segments.

Venue

Hilton Anaheim

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