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Filling study injection moulding- Find errors in the manufacturing process before production costs explode !

Injection moulding is the most commonly used production process in plastics processing. In this process, the material to be processed is liquefied (plasticized) by the injection molding device and then injected directly into the mold. The mould in the filling study during injection moulding is usually electrified. On the one hand, this serves to heat the mould at certain points in order to influence the cooling of the liquid material at critical points. On the other hand, it is also intended to prevent a poor filling pattern (e.g. due to unfavorable static charging).

In the tool, the material is brought back into its shape by cooling or seam reaction and removed as a finished part after opening the tool. The cavity of the tool determines the shape and, above all, the form of the workpiece.

filling study injection moulding
Injection moulding simulation of a bumper

The weight of the products that can be manufactured currently ranges from a few tenths of a gram to about one hundred and fifty kilograms.

To gain an insight into the filling technology of injection molded parts, the metering distribution in the injection molding machine expands over time from one valve to the next until it finally fills the entire empty space. The filling steps mainly show which areas have to be filled with certain time factors and show an insight into the technology and the possible optimizations. Any image that is created during the filling process is called a fill or fill pattern. In injection molding, the appearance, design of the filling and the filling process itself are the essential process parameters.

Many companies use filling simulation to map the injection molding process of plastic parts before production starts and to safeguard against possible production defects (e.g. air inclusions, warpage or shrinkage). The end result is the filling pattern of the component to be produced, which is suitable not only for defect identification but also for optimizing product manufacturing.

Filling simulation optimization

The filling simulation provides statistics on the manufacturability of plastic parts right from the start. If injection molding is viewed as an overall process that can be mapped in the simulation, it can be used to detect molding errors long before the mold is designed. In this way, injection molding processes can be optimized, and filling problems during subsequent production can be avoided right from the start.

Filling study injection moulding to determine the warpage

Warpage compensates for shrinkage in the component by cooling the material. This process takes place as long as there is still liquid material in the component and the plasticizer can escape. If the component freezes when the material solidifies it can no longer compensate for the shrinkage of the deformation-maintaining part. This leads to the temporary suspension of contractions in the component and can have either a negative or positive effect on the component behavior or the manufacturing process. To be on the safe side, it is advisable to map the injection molding process before the start of production as part of a filling study.

Engineers and experienced plastics specialists often simulate the entire injection molding process from the start of the material flow to the freezing and cooling of the material. In order to shorten the cycle time and also to reduce the deformation trend, industrial companies often use a filling simulation tool with which, among other things, the deformation curve can be determined and optimized.

Injection moulding in the filling study

If problems occur during mold filling, the filling study is the first step towards solving the problem. It provides you with solution approaches to eliminate errors and optimize your components. Our trained engineers will be happy to help you quickly and reliably with a filling study of your injection molding process !

Learn, how we can support you in the development of your products and also in the preparation of a filling study for injection moulding !

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