Plastics Molding Consulting
Just a short note to say thanks for your work on our molded bezel project. This was the first Moldflow
that will produce better parts. Particularly your suggestion to modify and taper the thickness at the
bottom of the groove to control the way the mold fills should get rid of a big knit line and make a much
better part. I never would have thought of doing that. Also your runner, gating and parameter data
should help the molder get good parts quickly, easily and with minimum “tuning” once the mold is
So I’ve certainly seen that a Moldflow analysis is worth doing and that you’re the right guy to do it.
Thanks for all the help.
My name is John High. I am a manufacturing engineer for Preformed Line Products. Our company
provides components to the power utility and telecom industries.
We have been developing a product that will give us the opportunity to have a presence in the Korean
power market. This new product requires a unique plastic extrusion process which Bozilla Corp. has
been instrumental in helping us develop. They helped us reduce the number of machining and testing
iterations needed by doing these iterations virtually using Moldflow. Bozilla Corp. worked with us to fine
tune the setup of each analysis to match the real world conditions as close as possible. They provided
a detailed meaningful report for each of the 3 design iterations. They worked hard to get each report to
us quickly, and each report provided valuable learning to help us move forward in the design process.
We have since produced and tested the extrusion tooling with good success. The analysis predictions
that Bozilla Corp. provided have matched our real world results very closely. Without Bozilla Corp.’s help
our process development for this product would have taken a lot longer, and would have cost a lot more
in labor and machining costs. Their reports also helped us learn a lot more about the extrusion process
which we can apply to future design projects.
As one of the world’s largest providers of hot runner systems, machine nozzles, temperature controllers
and sprue bushings for the injection molding industry, Synventive also provides Moldflow analysis with
our hot runners for customers in order to ensure a properly designed runner system for the customers
Synventive provides in-house Moldflow services, but many times has high demand and needs to
outscource many jobs. We need to ensure that we have a Moldflow Certified Consultant who has hot
runner knowledge, experience and is capable of representing Synventive.
Since Chris, the Chief Consultant at Bozilla Corporation, is a former employee and has years of
experience, he is a perfect fit for our business. Time and time again they have provided outstanding
cost-effective services with amazing turn-around times.
Our relationship with Bozilla Corporation is vital as we move forward in an ever-growing and demanding
Synventive Process Simulation Team
|Copyright ©2007 Bozilla Corporation. All rights reserved.
Completed Sun Roof project:
The major objective of conducting the analysis was two fold: 1) minimization of warp by using Moldflow
as a design tool, and 2) determine the feasibility of running the part in a 4000 ton press without the use
of gas assist. Historically, Yamaha's Sun Roofs have been gas assisted for strength and press tonnage
requirements. One of the potential major drawbacks of using the gas assist process are the inevitable
non-uniform walls that will occur resulting in warpage of the part. Careful part design, selection of gate
locations, selection of gas pin locations, and profiling the gas pressure can all help to minimize the
warping that will occur; but, typically all can not be achieved given today's part shapes and shortened
development cycles. A significant cost savings was also possible if the re-designed Sun Roof was
manufactured in-house on one of our 4000 ton presses. Standard hand calculations of the clamp
tonnage required was well in excess of 4000 tons and our in-house presses are not set-up for gas
We conducted the analysis in three phases. Phase 1 examined the basic part profile for warpage and
clamp tonnage requirements. Phase 2 added mounting features, ribs, bosses and further refined the
results of Phase 1. Finally, phase 3 consisted of confirmation runs of the optimized part using the actual
mold design furnished by Delta Mold of Charlotte, NC. Phase 1 major changes included an increase in
the number of gates from 4 to 6 and a resin change to reduce the fill pressure. Phase 1 predicted
results: total warpage at 11 mm and clamp tonnage at 2700 tons. Phase 2 changes included an
increase in the number of gates from 6 to 9. This change was to eliminate two potential gas traps in the
part and to examine the effects of additional gates on part warpage. Phase 2 predicted results: total
warpage at 5.8 mm and clamp tonnage at 2768 tons. Phase 3 confirmed that the actual mold cooling
circuits and gate locations did not significantly affect the warpage or tonnage requirements.
In summary, the final results have far exceeded our expectations. The actual part correlates very well
with the Moldflow predictions. Parts produced to date have exhibited no warp that can be detected by
the naked eye, exhibit a large processing window, have significantly increased our customer
satisfaction, and have resulted in a significant cost savings when compared to the old design. In-house
production of the Sun Roof has started and we look forward to a long successful product life. Again,
thanks for your dedication, knowledge, and expertise in assisting me with this successful redesign. We
will certainly contact you in the future for additional analysis projects.
Product Development Engineer
Yamaha Motor Manufacturing
showed the broken lids were in spec. Based on your analysis, we changed the lid molding process and
the material grade we use. And to make sure all this stays in check since this is a highly suspect area,
we changed our hinge flex test to a hinge impact test done at cold and room temperatures. The older
returned lids that would pass the hinge flex test would not pass the new impact test. We applied this
knowledge to the other sizes of lids we make and now all the lids we are producing pass the new impact
Product Development Manager