Accuracy of Flow Simulation on Plastics Injection Molding machine

I have recently been exposed to multiple articles and discussions regarding the implementation of flow simulation on injection molding machines. This is an intriguing topic which I advocate. Currently, this new combo method is proving difficult to line up the results from the analysis with the actual process on the injection molding machine. In order to successfully utilize this capability on an injection molding machine, several factors must be understood.

For those who have read my previous articles, you may appreciate that I strongly promote having the right person for the right job. In other words, the simulation engineer must have a complete and comprehensive understanding of plastics in order to be able to properly simulate the plastics injection molding process.

My suggestion is to always have a degreed Plastics Engineer with floor experience perform simulations on plastic parts. The reason for this advocation is to ensure that the simulation engineer virtually takes on the role of the process engineer. This makes certain that the simulation will properly emulate the injection molding machine process on the part being molded. Unfortunately, this is not always the case and the articles I have recently read do not touch on this very important factor. A virtual simulation cannot simply be executed, have the results taken to the floor, input into the injection molding machine and expect the molded part to perfectly match the simulation results. It’s not that easy due to many variables which must be considered.

Plastics injection molding optimization

For example, the simulation engineer (with the proper degree and experience) will understand the limitations and boundaries of the intended injection molding machine for that particular simulated part. It is not always necessary to know every specification of the machine and to input that specific data into the simulation. Most machines have a wide variation of capabilities that the simulation engineer will take into consideration. The simulation will then be executed with all of the necessary variables factored in for the injection molding machine, thus maintaining a high degree of accuracy between the simulation and the floor.

The difficult task is discovering those unintended variables that affect the process on the floor, e.g. material batch changes, colorant issues in the polymer, tool temperature variations that the press cannot record, physical changes within the tool such as polymer sticking to action within the tool, cold gates not opening and flowing when desired, cosmetic issues at the gate or within the part and the list goes on.

In order to capture these variables, the process engineer must have a method to identify them, or the machine must have instruments that can identify these variables. Once identified, the variables can be obtained by the simulation engineer or AI in order to make improvements in the process.

At Bozilla Corporation, Our Team provides an educated explanation of the differences between these two positions, Simulation Engineer and Process Technician, and bridges the gap in order to create a unified and successful process with minimal error.

In a world where the implementation of AI is becoming more common, it is critical to have a complete understanding of every phase of the plastic part manufacturing process in order to have a successful outcome. Without this information, the AI code will not be able to learn and make the necessary adjustments.

Contact Bozilla Corporation today and let’s discuss how we can successfully contribute to your project. Bozilla Corporation’s Injection molding Team has over 20 years of experience analytically and on the floor. We specialize in optimization, consulting, engineering, troubleshooting and Autodesk Moldflow software training. Additionally, our plastics engineers have a full understanding of polymers and how they influence an injection molded part. Your success is our success. Our skilled Team is focused upon meeting the goals and timelines of our customers.

images for this article courtesy of Engel, 800-942-0742,

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About the Author:

Chris Czeczuga is a Plastics Engineer, Injection molding expert, Military Veteran and the President of Bozilla Corporation. He has proven success with many Fortune 500 companies throughout the injection molding industry. A graduate from UMass Lowell, he is Expert Certified with Autodesk, has 20+ years of field experience, intimate knowledge of injection molding part, tool and feed system design. Bozilla Corporation’s success is built on providing the highest level of injection molding simulation and consulting advice to businesses who have short lead times, require an efficient, cost-effective molding process, and desire to produce a correct part the first time.