FMS Mold flow Analysis: Engineering Success Across the Life cycle
At FMS, mold flow analysis is driven by decades of hands-on manufacturing expertise, not just software operation. We translate data into actionable insights—optimizing your mold design from the ground up and accurately predicting potential production risks before steel is cut. Beyond supporting our turnkey projects, we offer this advanced simulation as a standalone engineering service.
Seamless Virtual Collaboration
Through our cloud-based collaborative platform, our engineering team integrates seamlessly with yours. Review analysis reports, discuss optimizations, and troubleshoot in real time—giving you the precise support of an in-house engineering department, no matter the distance.
First-rate Mold Solution Co., Ltd. delivers high-precision engineering services that seamlessly balance premium quality with cost efficiency. By leveraging advanced CAE mold flow simulation, our engineering team optimizes complex injection molding designs long before tooling begins.
This data-driven approach allows us to accurately predict polymer behavior, assess material options, and refine process parameters. Through detailed simulation, we analyze critical variables—including optimal gate location, runner efficiency, weld lines, air traps, shear stress, and clamping force—to eliminate potential molding defects proactively. By mitigating risks during the design phase, we ensure accelerated time-to-market and optimized production reliability for our clients.
For different molds, our molding analysis engineers often do:
1) Flow analysis
Predict product filled if hysteresis, whether playing, filling is balanced, with lines and pack wind position, filling the required injection pressure / clamping force sizes, into the plastic location / number / size are reasonable.
2) Runner balance analysis
For a multi-cavity mold cavity or family, can be automatically balanced runner system analysis, through the analysis, we can recommend the flow channel dimensions, how much of the flow channel dimensions, several cavities filled at the same time, to achieve flow balance.
3) Gate location analysis
Moldflow gate location analysis which is called Gate location Analysis, whose role is to automatically analyze the best gate location. When the model already exists in one or more of the gate, and then manually set the gate already exists, the system will automatically analyze the best location for the other gate.
4) Cooling analysis
Prediction mold cooling water layout is reasonable, what areas need to be strengthened cooling, determine the thickness of product design is reasonable to predict molding cycles.
5) Warpage analysis
Predict product deformation and X, Y direction shrinkage values, combined with the adjustment of water / hold pressure parameters / methods into the plastic deformation and thus provide the smallest possible options before making the mold deformation
6) Shrinkage analysis
Analysis of the materials forming the product, the molding shrinkage fit put the number, and the volume contraction, if sink mark .
7) Gas-assisted analysis
Predict gas-assisted molding gas penetration distance, penetration effect, the best location and airway inlet arrangement to assess the product gas assisted molding shrinkage and deformation, etc.
8) Core shift analysis
Mold core offset forecast trends and offset by correcting the mold design, reduce the process of filling the core of the impact strength of the weak, extended tool life.
9) Stress Analysis
Predicted residual stress distribution molded product and size.
10) Fiber orientation Analysis
It is to analyze and control the fiber orientation of the plastic, injection-molded parts in order to reduce shrinkage, warpage , and the floating fibers.
Many different types of fibers, including glass fibers, carbon fibers, silicon carbide fibers, synthetic fibers, boron fibers and the like, the simulation can be based on different fibers we percentage simulation. Fibers can improve the material properties are as follows:
1) over time, reducing material plastic deformation occurs and stress relaxation / 2) improve the flexural strengt / 3) Improve the tensile strength / 4) Improved heat distortion temperature
5) Improving the dimensional stability of the mixture
11) Overmolding analysis
Two-color molding molding products can be analyzed flows, warping and bonding situation.
12) Microchip Encapsulation IC chip package analysis
Predict chip package, thermosetting plastics in the mold cavity flow and curing conditions, flows on the impact of gold wire and pin
13) Underfill analysis
Optimization of thermosetting material molding conditions and filling dispensing model simulations predict various forms (I, L or … form) predicted injection pressure and clamping force of wind and demand forecasting package combines line position.
14) Birefringence Prediction
After forming the refractive index of refractive index difference can be manifested in the form tensor. General 0.1 The results for the optical parts is too large, it should be by adjusting the gate position, adjusting the process conditions or modify the product structure to achieve low residual stress. Asymmetric tensor indicate the occurrence of birefringence, the more serious the description of asymmetric birefringence more serious, actually see the “double word” the more obvious
Designing a good injection-molded part is dependent on many factors. Proper flow of the resin into the mold is one of them. Moldflow is a proprietary software program that was created to digitally simulate flow of resin through your part geometry. The resulting data that emerges will essentially help you design a part that will mold better.
I am a professional moldflow engineer, Moldflow analysis can provide you following benefits:
Moldflow Filling Analysis / Optimize gating / Optimize runner system / Predict fill pattern / Predict injection pressure / Determine clamp tonnage / Predict temperatures / Visualize shear rate / Visualize shear stress / Determine fiber orientation / Predict volumetric shrinkage / Predict sink / Determine venting / Avoid air traps / Locate weld (knit) lines / Develop optimum ram-speed profile
Moldflow Cooling Analysis / Find hot spots / Calculate time to freeze / Visualize uneven cooling across core and cavity / Determine uneven cooling between core and cavity / Define required coolant flow rates /Measure pressure drop in cooling system / Determine (and reduce) cycle time / Optimize the cooling layout
Moldflow Packing Analysis / Calculate proper packing pressure / Define optimum packing profile
Moldflow Warpage Analysis / Predict warpage / Find cause of warpage / Determine warpage due to orientation ./ Predict warpage due to differential cooling / Understand warpage due to differential shrinkage
Moldflow Gas-Assist Analysis /Determine optimized gas channel layout / Predict gas penetration / See gas permeation / Predict skin/core ratio Establish required gas pressure / Define optimized gas pressure profile /Refine spillover design
Moldflow Co-Injection Analysis / Compute skin/core ratio / Calculate skin/core distribution / Establish switch over points for skin/core (A-B) / Establish switch over points skin/core/skin (A-B-A)
Moldflow is very important tool for verifying mold design and product design, I can say it is 99.9% helpful, mold flow analysis has lots of advantages and will save a lot of money.
A good moldflow analysis has lots of benefits, although it is time consuming, the cost is much lower than the cost of trials during nights and days on a production injection molding machine. The difficulty is not to produce colored pictures but to explain to the customers the different results, some customers have enough knowledge to understand some others no.
The consumer product development process is much more complex than just creating a design and having a machine spit out material in a desired shape; plastics are not as inert as they seem and do not operate like static building blocks. The color maps created by mold flow analysis assist in adaptive changes of the design in order to create a quality product before the molding process actually occurs. This ensures that when a prototype or product goes into production, it is going to perform and behave optimally. Despite the overhead that it adds to the process, mold flow analysis more than makes up for this in terms of final quality. In fact, it has been considered a factor in keeping North American manufacturing competitive in the face of cheaper product development processes elsewhere. Furthermore, it demonstrates a commitment to quality, and is a good indicator of design and engineering firms who are competent, reliable, and produce quality solutions.
Mold flow analysis is the process of simulating an injection molding cycle with a particular plastic and analyzing the results. Mold flow analysis should occur before the injection molding process ever begins, through the use of specialized software that simulates the design of the part to be manufactured. Since the flow of the liquid material in the mold makes a massive difference to the behavior of the product, this step can save a great deal of effort down the road. This software creates color maps of different properties of the design as they would be reflected in the actual mold flow. These may include heating/cooling, fill pattern, injection pressure, potential air traps, shear stress, fiber orientation, and many more properties. Mold flow analysis is a careful, hands-on-process meant for experts.
I am an injection mold designer, and MOLDFLOW’s help in our design is unquestionable. When designing a new mold, we can hardly design without its guidance.you can get full support for gating selection and optimized for size, type, location, layout, design etc, complete runner layout, runner balancing, full manifold layout, design, dimensions, pressure drop, heating control, and full details of shear heat, stress on flow, complete cooling layout optimization for hot spots, layout design, water line sizes, thermal pins, check different types of inserts, insert materials, different types of water control, coolant type verification, cooling cycle temperature control, flow, turburlent flow, balance, overall tower/water manifold control effects, solutions to existing cooling issues or tooling issues, overall clamping force calculation and optimization, vent locations, force calculations for your moving slides, lifters, core pulls, effects of unbalnced flow on tooling, stress calculations due to filling effects, tool life, tool stress failure, overall tooling design review of support bars, moving actions, ejection based on full understanding of effects of molding on the tool design and tool life.
I am a product designer, I think that moldflow is very helpful to us in plastic product design. for example, thickness, thick/thin section, material selection, structural issues, weld line/flow control, fiber orientation controls, models for full FEA analysis of molded parts, answers to many engineering changes, virtual parts without tooling and molding, verifiy different ribing, flow leaders, minimize gating, produce parts with least cost of tooling, lower machine tonnage, lower molding costs, and reduce overall product development costs.
I think moldflow is very good at the choice of materials for injection molding. If you are not sure about which plastics material to use, you can verify different grades of plastics materials, compare and verify for warpage, tooling, processing. You may be also able to compare some structural properties and use moldflow for complete structual analysis, part weight optimization, compare mateiral weight, costs, processing, tooling. Thus you can make a completely scientifically analyzed decision about materials.
I am an injection molding engineer, in my opinion, Moldflow can full Optimization of Injection Molding and processing set up – See complete list of molding isssues that can be resolved through moldflow analysis, just to name few gas traps, weld lines, flow marks, flow lines, gate blemishes, jetting, hot spots, burns, cold spots, under packing, over packing, short shots, temperature issues, filling issues, warpage issues, shrinkage issues, fiber orientation, strctural failure due to molding, material issues etc., complete reference molding tryout set up, full control over molding process and overall reduction in molding costs through optimized cooling time and cycle time can give you thousands of dollars in savings with just one analysis.