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Moldex3D

Moldex3D is the world’s leading CAE tool for plastic injection molding. With Moldex3D, it is possible to simulate a variety of plastic molding processes to improve product design and manufacturability, as well as shorten the time-to-market. Moldex3D is available in three main packages: eDesign, Professional, and Advanced, together with the rich selection of add-ons, makes it easy to get a tailored solution that meets your specific needs.

eDesign offers an easy-to-use package including simulation of the full injection molding process: flow, pack, cool, and warp, enabling designers to test and validate their designs. The interactive interface, which facilitates the part and mold modeling and provides auto meshing technology, enables users to have efficient model preparation. The simple setup combined with the fully automated eDesign meshing allows the user to obtain product insights, visualize flow and thermal properties, and optimize the process without extensive CAE experience. 

Professional package gives the user more control and accuracy on top of eDesign Package. Key features that the Professional package adds are 3D Coolant CFD, BLM meshing, and compatibility with more add-ons. 3D Coolant CFD is required to perform RHCM (Rapid Heat Cycle Molding) and Conformal Cooling analysis. Moldex3D BLM (Boundary Layer Mesh) automated meshing with Non-Matching mesh technology facilitates better part and mold modeling that can produce results with greater accuracy. There is also a limited version of the Professional package, Professional Basic; this solution is limited to flow simulation, which can be useful for analyzing flow-dependent properties such as fiber orientation.

Advanced package provides all users, from product and mold designers to advanced CAE experts, with the ability to examine the details of all types of designs, from thin-wall molded parts to complex models with fine features. In addition to giving access to all add-ons, Moldex3D Advanced Package offers advanced hybrid meshing with more user control, as well as 2.5D modeling. Solve the most complex processes with great accuracy and efficient performance for every design.

An independent product series specifically for the IC Packaging industry applications is also available.

Flow

Simulation of the filling process (flow) is where most potential issues can be identified and fixed. Optimize gate and runner design with minimum weld lines, air traps, burn marks, and short shot problems. Control the process conditions such as injection time, melt and mold temperature, flow rate, etc. The flow simulation can also provide flow-induced fiber orientation, which will impact the part's mechanical properties.

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Weld Line


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Hesitation

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Flow Imbalance 

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Short Shot

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Pack

Evaluate gate freeze time and estimate the effective packing profile. Minimize defects such as sink marks and flash problems. Compute the shrinkage and required clamping force.

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Cool

Maximize the cooling efficiency to reduce the cycle time. Find hotspots and uneven cooling to minimize warpage

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Warp

Predict the final part shape, estimate shrinkage, and identify warpage causes. Warpage effects from fiber orientation, residual stress, and material viscoelasticity can be included.

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Moldex3D Studio

The user-friendly pre- & post-processor Moldex3D Studio allows for easy creation of good quality models, efficient evaluation of results, and automatic report generation. The intuitive ribbon-style interface lets the user complete the whole molding simulation workflow all within the same interface. Moldex3D studio also includes a comprehensive material database [1].



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FEA interfaces

Characteristics of plastic materials are extremely dependent on the molding process; however, process-induced properties, such as fiber-induced anisotropy, are not always favorable for the structural requirement of the final product. Simulation results such as fiber orientation and material anisotropy can be exported directly to most FEA software, e.g., LS-DYNA or ANSYS, via the FEA interface.[2] The Micromechanics Interface is a module that allows users to output material properties for nonlinear multi-scale material modeling in, for example, Envyo or Digimat.[3]


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CADdoctor

Integrated geometry healing tool enables multi-CAD data exchange, geometry simplification and verification, quality check for CAE, etc. Fix poor-quality geometry and make simplifications of complex features. Moldex3D CADdoctor helps to enhance mesh quality to bring more accurate analysis results

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Fiber

Fiber-reinforced plastics are widely applied in the industry as a means to increase the mechanical and thermal performance of plastic parts. These properties are highly dependent on the fiber length, orientation, and concentration, which in turn is dependent on the flow conditions in the molding process. Predict orientation, length breakage, and concentration and the effect on shrinkage and warpage. Moldex3D supports different types of fiber: short/long, flake, round/flat, etc.

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Other Features

  • 3D Coolant CFD and Transient cooling
  • Fluid-structure interaction (FSI)
  • Optics evaluation, flow or thermally-induced defects
  • Advanced hot runner modeling with moving pin
  • High-performance computing & parallel processing
  • Viscoelasticity
  • iSLM - Intelligent Simulation Lifecycle Management system 

Aside from conventional injection molding, Moldex3D also supports simulation of a wide array of different molding technologies:

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Multi-Component Molding (MCM)

  • Simulate insert molding, overmolding, and multi-shot sequential molding processes
  • Evaluate the interactions of different materials, and consider the material properties to minimize warpage and delamination
  • Detect potential re-melt issues
  • Estimate core shift with two-way FSI analysis

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In-Mold Decoration (IMD)

  • Provide wash-out index to better predict wash-off ink decoration of the film
  • Easy setup of IMD film boundary condition

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Co-Injection Molding (CoIM)

  • Visualize dynamic filling interactions of skin and core materials
  • Optimize geometry thickness and process conditions based on core breakthrough prediction
  • Identify temperature imbalance and pressure resistance for different materials

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Bi-Injection Molding (BiIM)

  • Define independent melt entrances and filling/packing parameters for different materials
  • Visualize the melt front advancement for each melt entrance and predict the weld lines to optimize gate design

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Gas/Water-Assisted Injection Molding (GAIM/WAIM)

  • Specify the gas/fluid injected from a single of multiple separate gas entrances or from the melt entrance
  • Optimize skin thickness and core-out ratio distribution to predict corner effect and blow through
  • Support push-back analysis in full-shot process to avoid the switchover mark and material waste

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Foam Injection Molding (FIM)

  • Analyze the filling behavior of the polymer-gas during microcellular foaming process
  • Obtain cell size and density distribution with considerations of cell nucleation and growth which can be output to Digimat
  • Evaluate the surface quality, bubble effects, weight reduction, tonnage reduction, shrinkage reduction, etc.
  • Supports MuCell® and chemical blowing agent (CBA) material simulation

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PU Chemical Foaming Molding (CFM)

  • Provide foaming kinetics for different by-products in chemical foaming processes
  • Predict the bubble variation and density distribution
  • Ensure a desired volume-to-weight ratio of the product

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Compression Molding (CM)

  • Control the process variation after the compression to decide the charge design
  • Visualize pressure distribution, volume shrinkage, residual stress distribution, fiber orientation, etc.
  • Predict potential molding defects, such as flashing
  • Integrate with LS-DYNA for more accurate compression molding process from solid deformation stage to liquid filling stage

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Injection Compression Molding (ICM)

  • Examine property changes in the compression molding process
  • Compatible with VE and Optics analysis  to optimize residual stress, shrinkage, and warpage

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Powder Injection Molding (PIM)

  • Simulate injection molding stage in the PIM process
  • Consider the impact on powder concentration and predict black lines due to phase separation of powder and binder (non-uniform powder concentration)

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Resin Transfer Molding (RTM)

  • Simulate the filling performance and the effects on different fiber mat types and orientation
  • Capture cure reaction trend during molding through viscosity and kinetics models
  • RTM Wizard with a seamless pre-processing workflow to enable the direct settings of ply groups, boundary conditions, and ply material groups
  • Supports import of draping result (LS-DYNA) into Moldex3D Mesh for more accurate analysis


[1] Material database: Thermoplastics materials, thermoset materials, molding materials, coolant materials, and mold materials. Also available in Designer interface.
[2] Moldex3D FEA Interface supports Abaqus, ANSYS, LS-DYNA, MSC.Marc, MSC.Nastran, Nastran, NX Nastran, and Radioss.
[3] Moldex3D Micromechanics Interface supports Digimat and CONVERSE.

CoreTech System Co., Ltd. (Moldex3D) has since 1995 provided the professional plastic injection molding simulation solution “Moldex” series for the plastic injection molding industry, the current product “Moldex3D” is marketed worldwide. More information at www.moldex3d.com