Moldflow Analysis Consulting

Designing an injection molded part?

Injection molding is a complex process! Vital to the success of any project is the ability to evaluate & identify part design and warpage related issues prior to "cutting steel." What happens if the part fails in application, warps, or if the quoted cycle time is not achievable? Who pays the price?

Since 1981, CAE Services has been providing Moldflow services for OEMs, product designers, mold builders, and injection molders. Today, we offer a turnkey solution approach; Part feasibility, FEA, Moldflow analysis, sampling support, and analysis implementation.

If you're looking to improve product to market cycles and need to "Get it Right the First Time," call us today and join our team of satisfied clients!

Filling Pattern with SVG

Filling analysis is the fundamental building block upon which all molding simulation is built. It predicts the filling patterns for a number of gating scenarios and identifies the one most beneficial to the part quality and molding efficiency.

Cooling Analysis solves the problem of providing both uniform and efficient cooling to an injection mold, leading to better part quality and increased profit margins through reduced cycle times.

Hot Spots - Without Moldmax

Hot Spots Eliminated - With Moldmax

Buckling Problem Identified

The ability to not only predict, but determine the cause of warpage is one of the real strengths of Moldflow analysis.  Our engineers use this information to significantly reduce or eliminate the warpage in your part, to avoid problems down the road!

Gas Assist analysis identifies the feasibility of achieving efficient gas penetration in areas designed to be cored out.

Gas Penetration Core

Thickness Fraction of Polymer B

Co-injection analysis will help determine the appropriate gate location and timing for shooting both the A & B materials. This optimizes the amount of B material being used and keeps it from blowing through the A material.

Injection-compression molding is often used in thin-wall applications to help reduce molded-in stress by filling plastic into a slightly opened (i.e., thicker) mold and closing the mold to complete the filling.  Analysis helps determine the best gate locations and the resulting decrease in clamp force requirements.

Compression Used To Create Thin Membrane

1st Shot (Clear)

2nd Shot (Black)

2-shot analysis requires balanced gate locations that avoid prominent knit lines. Air traps for the 2nd shot should be pushed to the parting line instead of up against the 1st shot material.

Core shift analysis identifies excessive shifting of deep cores due to pressure imbalance and its resulting effects on the thickness of the plastic walls.

Core Shift Displacement

DOE - Response Surface Plot

DOE analysis identifies which inputs are most influential and calculates their level of influence on any number of outputs.

Fiber orientation analysis is essential to accurate warpage predictions and helps determine the best gating and filling pattern to deliver the most advantageous fiber orientation.

Fiber Orientation Pattern

Balanced Compression Filling Pattern

Compression analysis identifies the best location for the placement of the “charge” to provide complete and balanced filling.

MuCell (microcellular) molding is a mechanical foaming process used to lightweight plastic parts and reduce warpage.  Moldflow analysis will help determine the best gate location and processing to achieve efficient foaming distribution.

Bubble Number Density

Volumetric Shrinkage

The Packing process is perhaps the most critical phase of the injection molding process because this is where much of the plastic shrinkage variations are developed.  Getting the gating and packing pressures right are the main goals of Packing Analysis.