Injection moulding is a process for manufacturing plastic parts by injecting a molten polymer into a mould.
Our experience allows us to assess any critical issues in the design of injection moulds and avoid the formation of defects on the moulded parts. However, in particularly complex cases or whenever faced with very strict aesthetic criteria, during the design phase we use simulation software that uses advanced algorithms to simulate the flow of molten plastic through the mould and predict how cavities will fill.
Several factors influence mould filling, including the geometry of the part, the type of polymer, the mould and polymer temperatures and the injection pressure. Thanks to filling analysis we can identify and correct any issues before starting production, increasing the efficiency of the moulding process and the quality of the end product.
What are the benefits of filling analysis?
There are various benefits associated with using filling analysis, including:
1. Identification and correction of melt filling issues;
2. Optimization of injection mould geometry;
3. Reduction in injection moulding cycle production costs;
4. Improved quality of the plastic product;
5. Reduction in plastic product development times.
Now let’s take a look at all these aspects in more detail.
1. Identification and correction of melt filling issues
Filling analysis can help identify any issues that could occur during the moulding process, such as gaps, deformation or other flaws in the moulded part. This allows our designers to correct these issues before commencing actual production, thus reducing waste and costs.
2. Optimization of injection mould geometry
Filling analysis can help optimize the geometry of the mould to improve the way the melt fills the mould cavities. This can improve the quality of the moulded part and reduce cycle times.
3. Reduction in injection moulding cycle production costs
Filling analysis can help reduce production costs by identifying any filling issues and correcting them before commencing production. This can help reduce waste and the costs associated with producing defective parts.
4. Improved quality of the plastic product
Filling analysis can help improve the quality of the end product by identifying and correcting any filling issues. This can improve customer satisfaction and the reputation of the manufacturer.
5. Reduction in plastic product development times
Filling analysis can be carried out during the product design phase, reducing the time needed to develop and test the product. This can help reduce the overall product development times and improve marketing speed.
Summary
Putting your trust in a competent partner like Csplast means putting yourself in the hands of competent designers capable of carrying out filling analysis and using the result to make real design improvements to customer projects. This is an important process for optimizing the efficiency of the injection moulding process, reducing production costs and improving the quality of the end product.
Below you can see a video showing an example of filling analysis which proved essential in the realization of the moulded part. In fact, there were two points in the product where bubbles formed and remained trapped, something which could have caused burn marks on the end product. However, thanks to appropriate simulation, our Technical Staff were able to identify where to position air venting valves.
Contact us if you are interested in learning more about this aspect of injection moulding or for any other need!