MOLD FLOW ANALYSIS 101: A PROCESS

PRIMER & KEY BENEFITS FOR MANUFACTURERS

A N E B O O K B Y N E W B E R L I N P L A S T I C S
WHAT IS MOLD FLOW ANALYSIS? The various steps of the mold flow analysis process
also offer specific benefits. Below are just a few
Mold flow analysis is a process whereby the injection benefits in each stage that manufacturers can
cycle is simulated, and the results are analyzed using expect.
specialized software. A vitally important step in any
large-scale manufacturing process, mold flow • Filling Analysis: Benefits in the filling analysis
analysis is most effective when it occurs prior to include the ability to predict the fill pattern, injection
launching a tool build. pressure, temperatures, and sinking. A defined
process around filling also allows for the best
HOW IT WORKS possible gating and ram-speed profile, among
others factors. Air traps can also be avoided through
Mold flow analysis is a software-enabled process that this process.
provides a simulation by mimicking the conditions of
• Cooling Analysis: The cooling analysis is critical in
the mold and resin when manufacturing a part prior
terms of locating hot spots, determining the time to
to going into production.
freeze, and setting the necessary coolant flow rates.
It also helps you determine the cooling flow rates
The materials used in the plastic injection molding
and cycle time.
process can vary in rigidity and pliability, among
other differentiating characteristics. Since these • Packing Analysis: In the packing analysis, both
materials behave and respond differently, it is crucial pressure and the packing profile are defined.
to leverage mold flow analysis to predict any • Warp Analysis: This component of the process
complications you might encounter. allows manufacturers to predict and anticipate warp
– identifying the cause(s) in order to implement
This simulation is achieved through the mapping of preventative measures.
various design properties, including: • Gas-Assist Analysis: Through gas-assist analysis,
important factors and considerations are evaluated
- Fill Pattern and determined. These include penetration,
- Heating and Cooling permeation, channel layout, and required gas
- Injection Pressure pressure.
- Air Traps • Co-Injection Analysis: The co-injection analysis is
focused on factors related to skin/core, such as the
- Stress
overall ratio, distribution, and switch-over points.
- And more

A well-defined mold flow analysis can offer

manufacturers a host of benefits. A significant
benefit is cost savings. The cost associated with
mold flow analysis is notably less than the dollars
needed to perform numerous trials on a injection
molding machine. The simulation process allows for
early identification of issues, such as warp, sink, and
fill issues.

Ultimately, the most important and fundamental

benefit of mold flow analysis is its ability to prevent
issues, errors, and unnecessary costs before
manufacturing.

Effective analysis is a collaborative effort. By including

all essential manufacturing personnel in the analysis,
companies can avoid a siloed approach in which a
designer operates in a vacuum and information and
knowledge are not shared or freely offered.
WHEN TO PERFORM A FILLING attributes required of the person performing the
analysis that will determine whether it is executed
ANALYSIS correctly, producing clear and actionable results.
Filling simulations are utilized primarily for either
fine-tuning a new mold design before cutting steel The first requirement of this individual – often
or troubleshooting issues with a current mold. referred to as a simulation analyst – is having a
thorough knowledge of the materials, as well as
While analyses offer numerous benefits, as with any manufacturing, processing, and tooling. While
business function, it is essential to evaluate the software is a critical piece of the analysis, it cannot
process within the context of your company and make up for an inexperienced operator. You can
manufacturing system to determine if the potential have the best program in the world, but if the
exists for an adequate return on investment. person using it does not understand the technology,
it will not be effective.
Before deciding to perform a filling analysis,
manufacturers should have a clear picture of their A simulation analyst must be able to serve as a
objectives. translator. They will be in charge of conveying the
simulation results and explaining what they mean to
"WHAT DO THEY WISH TO GAIN key personnel, such as the processor.
It is also imperative that the analyst has access to
OR LEARN THROUGH THE design information and can communicate with the
ANALYSIS?" design team and other key staff members.

This should be developed along with cost estimates With these specific requirements and skills in mind,
so that the two can be examined to determine if the manufacturers should consider partnering with a
cost of the analysis is justified. company that can provide seasoned professionals
with extensive experience performing fill analyses for
Analyses and data are great, but if they are not a variety of clients. New Berlin Plastics partners with
utilized, then the time and money invested in original equipment manufacturers (OEMs) and tiered
producing and analyzing reports are wasted. It is not suppliers that require high-quality products,
uncommon for companies to create systems to engineering services, and value-added activities
evaluate processes and gather data, only to have from a single supplier. New Berlin Plastics’ advanced
reports sit on a shelf and collect dust. It is important technologies and processes, combined with an
to secure a commitment to the analysis effort within expert team, will help to ensure that your firm
your organization, buy-in from key stakeholders, and executes an effective and informative analysis to
agreement that reports will be reviewed, and their produce a product which meets high-quality
findings used to improve processes. standards and stays within budget – results of which
you can be proud.
As part of the buy-in process, manufacturers must
also ensure that their firms recognize that the results
of the analysis may be less than favorable and could
warrant adjustments for “the greater good.”
Additional cost and delays on the front-end,
however, can often prevent delays in the final
delivery of a product or part, along with significantly
higher costs had production proceeded with a
flawed design or process.

THE POINT PERSON FOR A

FILLING ANALYSIS
A critical component of a filling analysis is who
should conduct it. There are specific skills and
MOLD FLOW ANALYSIS FOR weakening the material and causing aesthetic issues.
For this reason, gates must be strategically
SIMILAR PARTS positioned to allow the melted material to both fill
Efficient companies are continually looking for ways and pack the mold.
to avoid “reinventing the wheel.” This is certainly
true of a mold flow analysis. If another mold exists The simulation also allows the analyst and other key
with key features that are similar to the mold personnel to assess cooling lines in the mold design.
undergoing analysis, the results can be applied to Cooling lines impact whether a part warps, or in
some degree to the similar mold. Correlations can what way it warps. By simulating both the heating
be helpful, and any errors based on the differences and cooling of a mold, the warp of the part can be
in the molds can be corrected during further analysis induced. This process can help ensure that necessary
and testing. adjustments are made to optimize part integrity.
Heating and cooling simulations also aid
OVERCOMING COMMON manufacturers in estimating production times and
temperatures and then adjusting as necessary.
CHALLENGES AND BARRIERS
A mold flow analysis allows production teams to
Plastic injection molding is not without its
identify any areas in which air is trapped as part of
challenges. The proactive processes and real-time
the mold filling process. Trapped air can be
adjustments performed through mold flow analysis
addressed by ensuring proper venting in the tool.
and simulation address many of the common pitfalls
Adequate venting is critical to ensuring both part
manufacturers encounter with regard to injection
quality and the proper flow of materials within a
molding.
mold.
Among such solutions is addressing “short-shots,” or
portions of the mold in which the material may not ADVANCEMENTS AND TRENDS
be adequately filling. This is an area in which
Advancements in technology have offered new
simulation is vital for proactively adjusting the
opportunities in the manufacturing industry. One
process or part to optimize performance.
area in which this is increasingly evident is cloud
computing. This single innovation is perhaps the
Additionally, a simulation helps identify weld lines,
most critical development in computer-aided
or areas at which two flows join together and “weld”
engineering today. Cloud technology makes
the material. Once located via the simulation, welds
computing exponentially faster by connecting
can be examined to determine their structural
multiple computers and systems.
integrity and fitness.
With regard to mold flow analysis, cloud-based
Material performance is also a challenge that
solutions can immediately meet the demands of
simulation takes into account. Not all resins and part
numerous users. As the number of manufacturers
designs are compatible, and simulation software
using cloud-enabled mold flow analysis solutions
provides readings and measurements related to the
increases, so too will the amount of data generated.
filling plastic’s pressure. This information can help
This data will, in turn, help providers refine their
identify potential issues in production.
offerings, and it could also serve to provide shared
knowledge and insights within user communities or
Information gleaned from simulations can aid
other crowd-sourced repositories.
designers in choosing gate locations and
determining gate sizing. Factors such as flow
distance and part aesthetics are important
considerations when setting gate locations. The
sizing of the gate is an especially crucial
consideration, due to the potential for shearing and
packing of the part. Each type of resin has a unique
shear rate limit or the point at which chains of
molecules are re-stretched beyond capacity, thereby
KEY TAKEAWAYS A Mold flow analysis represents the intersection of
technology, R&D, and risk mitigation. Manufacturers
To recap, manufacturers looking to improve that choose to implement simulations into
performance and minimize errors in their injection pre-production will reap the benefits in process
molding process through a mold flow analysis should optimization, cost savings, reduction of errors, and
remember the following key considerations: improved part quality.

1. Develop a Plan - Begin with a clear and

well-defined list of objectives. This will help inform
IN YOUR CORNER
the cost-benefit analysis/determination of ROI. At New Berlin Plastics, we know what makes an
2. Crunch the Numbers and Determine the ROI - excellent mold flow analysis. We offer custom
Evaluate the process based upon your company’s solutions to help you improve your firm’s processes
current situation and goals in order to determine if while protecting your bottom line.
the potential exists for an adequate return on With a variety of services and capabilities, we can
investment. support you throughout your project’s life cycle.
3. Consider the Timing - Simulations are most
helpful when performed prior to production – when By employing advanced technologies and processes,
fine-tuning a new mold design prior to cutting the we can ensure that your final product meets and
steel for the mold, or troubleshooting issues with a beats your expectations.
current mold.
New Berlin Plastics’ knowledgeable team has years of
4. Collaborate - Breaking down silos and fostering a
experience performing filling analyses for a wide
culture of information and knowledge sharing is an
variety of complex, tight tolerance, parts for medium
important element of an effective analysis.
to large OEMs from diverse industries.
5. Commit - Ensure the team is committed to the
analysis and all parties agree to review reports and Contact us today to learn more about the New Berlin
findings for process improvement opportunities. Plastics difference and to discuss a custom solution
6. Hire the Right People for the Job - Hire a for your company.
simulation analyst who possesses the specific skills
and knowledge necessary to correctly execute
simulations and produce reports that are clear and
actionable.
7. Watch Technology Trends and Opportunities -
As previously stated, technology has a significant
impact on the manufacturing industry. Developments
and new offerings have the potential of bolstering
your scientific injection molding practices,
streamlining processes, and improving overall
workflows and quality. It is important to remain
abreast of trends, not only with regard to cloud
computing but in terms of other new technologies as
well. Emerging technologies can represent added
efficiencies and other potential benefits to
manufacturers.
8. Keep an Open Mind - It is important to recognize
that the results of an analysis can be less than
favorable and could warrant adjustments. A small
investment in process improvement at the onset can
prevent considerable recovery costs or lost profit
later in production.