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Jun 8, 2023

Plastic Injection Mould Design Modelling Software | Ledwell Uses State of the Art Flow Modelling and Simulation Software

Commenting on plastic injection mould design modelling and moulding simulation software, Benn Simms, Managing Director of Ledwell said, “The importance of injection moulding simulation in mould tool design cannot be overstated.  Here at Ledwell we use state of the art software to help us design our mould tools.” Benn went on, “that said, there is no replacement for the knowledge and skills that our engineers have.  The mould tool design software enhances those skills”.

Benn explained:  Creating high-quality injection moulded parts is crucial for our client’s successful production. To achieve this, we rely on advanced design modelling software that allows us to analyse and optimise the design and flow of their injection moulded parts. This technology, known as injection moulding flow simulation, has revolutionised our Industry.  It provides our designers and engineers with valuable insights and data early in the development cycle.

Let me explain a bit more:

What is Injection Moulding Simulation?

Injection moulding simulation involves the use of sophisticated software programs to create virtual simulations of the injection moulding process. By inputting the CAD model of the part or mould tool, the software generates a finite element mesh that accurately represents the part. This mesh serves as the basis for analysing the complete injection moulding process, predicting and visualising what happens at each stage of the cycle.

Benefits of Injection Moulding Simulation

Optimised Filling and Packing Phase: One of the key benefits of injection moulding simulation is its ability to optimise the filling and packing phase of the process. By analysing the filling characteristics, such as filling patterns, pressure requirements, temperature maps, and air-traps, the simulation helps determine the optimum number and position of gates. This insight allows our designers to make informed decisions that result in better-quality parts.

Reduced Time and Cost: By using injection moulding simulation, our production engineers can minimise the number of physical tool trials required. This not only shortens the time-to-market but also reduces the overall cycle time and scrap rate. Additionally, the simulation helps identify potential issues, such as surface defects, weld lines, and sink marks, early in the design phase, saving time and resources that would otherwise be spent on tool modifications.

Improved Cooling System Efficiency: The cooling phase of the injection moulding process accounts for a significant portion of the total cycle time. Injection moulding simulation allows for the analysis of the mould’s cooling system function and efficiency. By optimising the cooling circuit parameters, such as the use of high-conductivity metal inserts or baffles, our designers can maximise heat-removal efficiency and produce high-quality parts in the shortest time possible.

Warpage Analysis and Solution: Injection moulding simulation is also invaluable in identifying and addressing part distortion or warpage issues. By analysing variations in shrinkage driven by factors such as volumetric shrinkage, pressure, crystallinity, stress relaxation and orientation our designers can make design modifications or adjust process parameters to achieve stable and optimal solutions.

Benn concludes: There are several design modelling software options available that specialise in injection moulding simulation. These software programs provide a range of features and capabilities to streamline the design for manufacturing (DFM) process and enhance the overall productivity and efficiency of injection moulding operations.

Injection moulding simulation has become an essential tool for injection moulders, generally, in the design and production of high-quality injection moulded parts. By using our advanced design modelling software, Ledwell gains valuable insights into the injection moulding process, optimises design and process parameters, and reduces time and cost associated with physical tool trials. With the ability to simulate and analyse the filling, packing, and cooling phases we can produce higher-quality parts and improve productivity.

To find out more about Ledwell’s injection moulding simulation, contact Benn Simms Managing Director of Ledwell.


Injection Moulding