Tools and dies are very expensive to make, and if they are not designed correctly they can be equally expensive to modify. Tool designers are expert in designing for various types of polymer moulding, injection, blow moulding, extrusion moulding and thermoforming. All these processes have particular requirements and settings for each different part. Analysis can prevent problems by identifying them before they arise.

Using process simulation software it is possible to predict the behaviour of the polymer in the mould before any metal is cut. This means that the design can be changed instead of the tool – a much cheaper option.

Our associated companies provide a complete range of injection moulding process simulation services. The analyses available are: Filling Analysis, Runner Balancing, Packing Analysis, 2D Cross-Sectional Cooling Analysis, full 3D Cooling Circuit Analysis, Shrinkage and Warpage Analysis, Co-Injection, Cascade Injection Moulding, and Gas-Assisted Injection Moulding These analyses will help identify moulding problems such as unbalanced cavity filling, gas traps, weld and meld lines plus excessive filling pressures and melt front temperature drops.

FEA Software Showing Potential Problem Areas.

Finite Element Analysis can predict whether or not a part or whole product will fail to meet Australian Standards. It will identify excessive stresses, strain, and deflection. It will also show if too much or too little polymer is being used. This helps reduce and optimise material volume usage. FEA can also describe polymer visco-elastic behaviour such as creep in the analysis, as well as impact loading and design for elevated service temperatures.

LP&A prepares the brief to guide the analysis and then interprets the results for our clients and ensures that the recommendations are incorporated in the tool designs.