SIMULATION SERVICES

Plastlabs has over 15 years of experience on MFA simulations, material engineering and injection moulding processes from wide range of industrial applications: automotive, electronics, medial instruments, mobile industry, micro scale sensors and household applications. We operate on customer case studies around the clock to provide the improved results and solutions on customer projects.

 

As a finalization of MFA case study we supply a comprehensive report including clearly understandable description of problems and proposed improvements. Generally case study report is a combination of 15-20 page report and over 10 clearly visualizing video animations. All Plastlabs MFA simulation studies are made with latest version of Moldex3D advanced solver with utilizing accurate BLM hybrid meshing technology. Simulation simply can’t get more accurate than that!

PRODUCT & TOOL DESIGN VALIDATION
  • Product development improvement
  • Design - simulation – design iteration loop
  • Reduces product development time
  • Improves product quality
  • Processability estimation
  • Points of concern
  • Gives optimal process parameters for 1st tool trials
  • Replaces 1st moulding trials (virtual moulding trial)
  • Saves money and time (first tool modification costs)
Moldex3D advanced MFA simulations is powerful design tool on product development phase. It enables fast design checks and product quality improvement cycles. Ideally MFA simulation replaces 1st proto moulds and saves time and money of first tool modification round. Commonly one design validation MFA analysis lead time is 48 hours and costs less than 40% of typical tool modification costs.
PRODUCT & TOOL DESIGN VALIDATION
TROUBLESHOOTING & ROOT CAUSE ANALYSIS
  • Find root causes on quality issues
  • Point out processing problems
  • Find solution to problems
  • Improve part quality 
  • improve processability
Moldex3D accurate MFA simulation is an ideal tool to find root causes and solutions to product design and IM-process based problems. Troubleshooting simulation gives on majority of the cases applicable solution to the problem without need to go for statistical DOE analysis. 
TROUBLESHOOTING & ROOT CAUSE ANALYSIS
CYCLE TIME OPTIMIZATION
  • Optimized processing time

  • Optimized cooling time

  • Mould cooling efficiency

  • Component design optimization & cooling time reducement

  • Effect of automatization

Nordic simulation has 2 decade experience on plastic manufacturing processing: moulding trials, FOT trials, setting up new process, mass production. This experience is a base for our accurate cycle time estimations and cycle time improvement. Cycle time simulation evaluates processing time steps and component’s required cooling time. Optimizing the component design has big affection to process cycle time. Which can be easily be converted to profit and improved ROI ratio.
CYCLE TIME OPTIMIZATION
MULTICOMPONENT & OVERMOLDING SIMULATIONS
  • Processability / process window

  • Proposed process parameters

  • Optimized process guidelines

  • Visual quality predictions

  • Multicomponent shrinkage values

  • Residual stress level (due to restricted shrinkage)

  • Warpage predictions

  • Root cause for warpage mechanism

Multicomponent warpage estimation, visual defects, adhesion indicators, material washout predictions. There’s wide range of analysis possibilities that multicomponent simulation can give on your component design. Whether it is case of validation or just simply improviement of design or IM process.
MULTICOMPONENT & OVERMOLDING SIMULATIONS
LSR SIMULATIONS
  • Ideal gate positions

  • Mold filling pattern

  • Short shots

  • Air / gas traps

  • Shear rate prediction

  • Premature curing

  • Mold curing sequence

  • Mould heating / thermal distribution

  • Curing reaction & cycle time

Moldex3D advanced flow solver has great benefits to validate LSR mould specification and LSR process. Moldex3D has comprehensive material library for commercial Silicon rubber grades.
 
LSR SIMULATIONS
OPTICAL SIMULATIONS
  • Raw material recommendation

  • Stress analyses / Birefringence levels

  • Optical retardation

  • Shear rate analysis

  • Ideal process parameters

  • Ideal gate dimensions

  • ICM / Concentional processing

  • Weld lines

Optical component quality is highly dependent on geometry, gate dimensions and processing. Problems on any of above decreases optical quality and may cause plastic part rejection.
OPTICAL SIMULATIONS
IML SIMULATIONS
  • Ink washout indicators

  • Film material washout indicators

  • Accurate shear rate predictions at gate – cavity interface

  • Proposal for ideal gating to reduce / eliminate washout

In-mould labeling (decorational, functional) simulations gives reliable predictions for ink, material washout during processing. plastic film caused restrictions to cooling efficiency. Warpage predictions. And naturally the clearly defined description of processablity.
IML SIMULATIONS
FIBER REINFORCED COMPONENTS
  • Raw material recommendation

  • Processability / process window

  • Fiber orientation

  • Proposal for ideal gating

  • Warpage prediction

  • Details for warpage causing mechanism

  • Shrinkage rate

  • Cycle time estimation

Glass, carbon, kevlar, mineral additives, only as a few examples are affective way to boost plastic part mechanical or other functional properties.
FIBER REINFORCED COMPONENTS
INSERT MOULDING
  • Guidelines for insert component specifications

  • Analysis of insert component mechanical stiffness

  • Warpage analysis of metal – plastic component

  • Details of warpage causing mechanism

  • Shrinkage / restricted shrinkage

  • FSI stress analysis

  • Process window

  • Indication of problems & description of improvements.

Metal inserts are effective way to decrease wall thickness and increase structural stiffness, or add electro mechanical functions to plastic parts. Nordic Simulations engineers have a long experience of simulating industrial insert moulding processes and set up customers design guidelines for insert moulding components. e.g. Various metal inserts for structural or decorational applications, electronics overmoulding including stress analysis on insert – plastic interface.
INSERT MOULDING
MICROMECHANISM SIMULATIONS
  • Raw material recommendation

  • Ideal gate position layout

  • Weld line positions

  • Warpage Prediction

  • Detailed explanation for warpage causing mechanism

  • Fiber orientation

Accurate simulations of gear wheels, sensors, sliders, plastic springs or micro scale electronical component housings. Next generation high tolerance geometry inspection tools: Dimensional movement on X,Y,Z component, Statistical investigation and shape shifting curvature visualization.
DOE ANALYSIS
GAS ASSISTED
  • Evaluation of gas penetration
  • Part structure evaluation (cross sectional)
  • Wall thickness
  • Cycle time
  • Process parameters
  • Ideal melt and gas entrance positions
  • Overflow & venting positions
Gas assisted MFA simulation provides the ability to study polymer and gas flow behavior within a part model. And see how design modifications affects of polymer structure and product guality . 
GAS ASSISTED
DOE ANALYSIS
  • Find optimal process parameters to achieve target quality criteria.
  • Investigate which parameter has biggest affection to desired target. 
  • Variables (injection rate, pack pressure & time, cool)
Moldex 3D DOE analysis is very effective tool to investigate part design and processing relation. Commonly it is used to find optimal processing parameters to fullfill products quality criteria. Or adjust some critial area dimensions for improved fitting other components.
DOE ANALYSIS