Accurate Multi-Component Injection Molding Simulations with Moldex3D

The goal of multi-component injection molding is to cost-effectively produce plastic components with complex functions, excellent tactile properties and an appealing design without the need for subsequent corrections. Simultaneously processing two materials in a single part opens up new possibilities in terms of functionality, such as stiffness, flexibility, transparency, color, insulation, and tactile properties. However, this process involves genuine technical complexity. How can reliable adhesion between the materials be ensured? How can interface defects be avoided? How can different shrinkage and deformation properties be controlled? This is exactly where Moldex3D comes into play. 

With Moldex3D users can simulate, visualize and predict every phase of the process, even before the first mold test takes place. This results in greater precision, speed and reliability throughout the design and validation process.

Moldex3D is a powerful tool fto identify risks early on, adjusting designs, and validating material and process parameters before physical production begins.
With the Bi-Injection module users can specify a precise injection sequence, select materials for each phase, define independent injection points and set corresponding cycle parameters, such as pressure, injection time, and temperature.

Creating a CAD model is the first step to set up a two-component injection molding simulation. The model must contain one or two volumes that represent the materials that ing to be injected, either sequentially or simultaneously.
Prior to the calculation it is critical to create a high-quality volumetric mesh for the simulation model. Moldex3D’s integrated BLM meshing technology generates a volumetric mesh with 11 element layers, which ensures accurate results. Accordingly, the process parameters and the Moldex3D solver must be defined.

Once the simulation is complete Moldex3D provides key results, including fill rate, temperature distribution, potential weld lines, internal stresses and a prediction of part deformation and shrinkage. This data can be used to evaluate bond quality between materials, detect potential defects and simulate various injection molding scenarios and material combinations.

For further information and questions please feel free to contact us.