Mold Filling & Packing Analysis


In a Mold Packing analysis, we identify and evaluate conditions found in the second stage of fill that can contribute to excessive warpage and tolerance inconsistencies. Examples of these conditions may include:

  • Excessive volumetric shrinkage problems
  • Potential sink marks
  • Premature gate freeze off
  • Poorly located gas traps

The results we typically evaluate are…

  • Melt front pattern
  • Fiber orientation
  • Shear rate
  • Shear stress
  • Knit lines
  • Gas entrapment
  • Pressure distribution and temperature differential

By optimizing the manufacturing performance at this stage, Shadow will maximize your product’s quality and strength due to molding. These results are then coupled together with the Mold Packing analysis to produce valuable insight into your mold’s performance.

Injection molding analysis is a very important analysis to perform before mold construction. Knowing your results before first shots can differentiate a successful product from an unsuccessful one.

In a Mold Filling analysis, Shadow generates the proposed part geometry in either 2.5-D shell or 3-D solid tetrahedral elements. We model the complete runner system including the type (hot/cold), size and location. Then, as needed, we will modify the design to develop a more advantageous layout to optimize the manufacturing performance during the first stage of fill.

Many questions can be answered by running this analysis:

  • 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?
  • What are my clamp tonnages for this mold?
  • What is the estimated cycle time?

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