Injection Molding Analysis   Injection mold analysis is a complicated, but very beneficial analysis to perform. Knowing your results before first shots in the mold is key to a successful product launch. Questions such as: "Can this mold be filled?", "How should the cooling be designed in the mold?", "Will this part warp out of tolerance?", "What is the correct material to use?", "Will this part fit in the molding machine?", and "What is the estimated cycle time?" are easily answered during this type of analysis.  Do you run more than 3 analyses per year?  If so, then we can help you save money with our Mold Flow Analysis Collective.  For more information about this offer and our special pricing program, please contact us at (281) 789 - 7520 or via e-mail at Info@shadowpolymer.com .   True 3-D Analysis At Shadow, we use the next generation of flow simulation software called Moldex3D.  Our complete set of software is capable of providing customers with state-of-the-art  FILLING, PACKING, COOLING, WARPAGE, FIBER, THERMOSET, GAS-ASSIST, MULTI-COMPONENT MOLDING (MCM), and INSERT MOLDING analyses in FULL 3-D.  By utilizing solid tetrahedral elements, our analysts can accurately capture all of your part's unique features without excessive modeling time and problematic assumptions.  Three dimensional simulation allows the observer to witness detailed flow phenomena that are typically missed when using conventional Hele-Shaw flow theory (a.k.a. 2.5-D or shell analysis).  Phenomena such as fountain effects, vortexes, pooling, and internal voids (bubbles) are easily identified and fixed.  So whether your part is thick or thin in nature and made of a thermoplastic or thermoset, we can help.  Contact us today for a full 3-D analysis on your part.         Mold Filling & Packing In a Mold Filling analysis, our staff generates the proposed part geometry using either 2.5-D shell or full 3-D solid elements. Next, we model the complete runner system including hot and/or cold type, size and location. Then, if needed, we modify the design to a more advantageous concept in order to optimize the overall molding conditions. These molding conditions typically include: Melt front pattern and orientation, shear stress, weld line integrity, gas entrapment, as well as, pressure and temperature distribution. We, then, maximize product quality and strength by optimizing the first stage filling while improving and balancing the pressures and flow characteristics of the mold. Thereby, fully balancing the runner system and mold design. In a Mold Packing analysis, the software in conjunction with the Mold Filling results produces packing results identifying conditions found in the Second Stage of Filling. We identify and reduce the potential for differential volumetric shrinkage and sink marks that may contribute to warpage and/or part tolerance inconsistencies. Mold Cooling Using an existing or proposed cooling layout, we perform a Mold Cooling analysis by creating the water channel geometry in the finite element model (FEM). Then, we setup the initial simulation utilizing experience-based cooling system parameters. In this type of analysis, we can identify conditions that may contribute to an extended cycle time, unbalanced or non-turbulent coolant flow, hot spots in the mold and excessive warpage or shrinkage. Using this knowledge, we correct the circuit problems in order to maximize overall coolant effectiveness. Warp & Shrink Using the Filling, Packing and Cooling results, Shadow can perform a warpage deflection study which identifies and presents your part's deformation predictions. In addition, this warpage can be broken down into its major components -- differential shrinkage, differential cooling and molecular/filler orientation. This service remains very popular among our customers who examine their part’s dimensions throughout the entire molding process. Fiber Orientation Using this filling integrated type of analysis, our staff is capable of identifying and presenting results based upon your part's glass fiber orientation. This analysis identifies fiber effects not only through the thickness of the part, but also on the molding surface. Negative fiber effects can significantly contribute to differential shrinkage, poor weld line integrity and reduced strength in critical areas of the part.