3D Design and Modelling.
We have extensive experience in the professional design of plastic parts for the automotive industry. In addition, we have an excellent theoretical and practical understanding of plastics processing. Our projects undergo continuous feasibility and optimization analyses in respect of the injection mold design, as well as its application in the production process. We use CATIA V5 and SolidWorks software to design.
ANALYSIS AND SIMULATION
For evaluating the strength and stability of parts designed by ourselves, in many cases it is necessary to carry out a structural analysis. This allows the observation of the distribution of stresses and strains at an early stage of the project. Simulations of this type are made using professional software based on the Finite Element Method (FEM). This procedure allows us to predict the behavior of the product in terms of the actual loads. The results obtained are helpful to make continuous corrections and modifications but (what is) most importantly, this allows a realistic reduction of the time and costs associated with the design and development of the product.
Complementing the structural analysis services, we offer a full range of 3D plastic injection simulations:
Fill – the first stage, which is the basis for further simulations, allows analysis of the cavity filling, including:
- selection of the optimal gate placement, this takes into account the dimensions of the part and the limitations present in the design of the injection mold;
- defining and optimizing the cavity filling time;
- determining the distribution and peak pressures in the mold cavity, as well as the overall pressure drop across the whole mold including the feed system;
- detection of air traps, position and quality of weld/meld lines, the effects of ‘hesitation/ racetracking’ and the minimum clamping force and other associated effects.
Pack – performing a quick filling analysis is not enough and each time must be coupled with packing analysis often called “pack and hold stage”. This critical step allows:
- determination of the time, pressure and packing profile;
- an analysis of the volumetric shrinkage, which directly impacts the dimensions and quality of the molded part;
- to correctly estimate the required clamping force, which in the packing phase could be much higher than the value estimated in the filling phase,
- an analysis of the residual stresses, which directly impact on the part deformations.
Cool A detailed cooling analysis of both part and injection mold with the possibility of simulating the conformal cooling channels and high conductivity inserts (i.e.BeCu).
Warp – a detailed part deformation analysis due to differential shrinkage, differential orientation, differential cooling. This simulation summarises all the previous stages.