How Does Mold Flow Analysis Improve Plastic Injection Molding Design?

Mold flow analysis is a critical component of modern plastic injection molding design that uses computer simulation to predict and optimize the injection molding process.

What Mold Flow Analysis Simulates:

Fill Analysis:

• Plastic flow patterns through the mold
• Fill time and pressure requirements
• Weld line locations and strength
• Air trap identification
• Hesitation and race-tracking issues
• Short shot prediction

Pack and Hold Analysis:

• Pressure distribution during packing
• Sink mark prediction and severity
• Volumetric shrinkage analysis
• Gate freeze-off timing

Cooling Analysis:

• Cooling channel efficiency
• Temperature distribution
• Cooling time optimization
• Hot spot identification
• Coolant flow simulation

Warpage Analysis:

• Part deformation prediction
• Causes: differential cooling, fiber orientation, shrinkage
• Compensation strategies
• Dimensional accuracy verification

How Simulation Improves Design:

• Gate Optimization – Find ideal gate location, type, and size
• Runner Balancing – Ensure even fill in multi-cavity molds
• Cooling Design – Optimize channel layout for uniform cooling
• Defect Prevention – Identify and solve issues virtually
• Process Window – Establish robust processing parameters

Software Tools:

• Autodesk Moldflow
• Moldex3D
• SolidWorks Plastics
• Sigmasoft
• Cadmould