During construction, making changes or modifications early in the design process, rather than, after cutting the steel, is highly recommended. In fact, certain changes are very costly after the mold-maker has begun his work. For this reason, Longterm has purchased advanced computer software that can simulate potential defects or flaws in the mold design prior to design approval.

Flow analysis is the first stage of the molding simulation process. Flow calculates the melt front advancement that grows through the part from the injection location, and continues until the switch-over point to packing. Flow analysis provides the ability to simulate, identify, and optimize the process to avoid molding uncertainty or resolve an existing injection molding problem.

Packing analysis builds on the results of the filling analysis by extending the first stage of the injection molding process into the packing phase. This second stage fills the non-filled portion of the mold with additional material to compensate for the loss in volume as the material shrinks. The part is then held under pressure while it solidifies.

Flow analysis evaluates or determines the following:

  • Uniformity of fill
  • Number of gates
  • Gate size and location
  • Weld line location
  • Air entrapment
  • Pressure & temperature
  • Shear rate, shear stress
  • Part designs
  • Processing conditions
  • Hot runner sizing
  • Sequential valve gating
  • Runner balancing

Packing analysis evaluates or determines the following:

  • Gate freeze time
  • Packing pressure profile
  • Volumetric shrinkage
  • Sink location
  • Clamp tonnage/machine sizing