Injection Molding Analysis 2.0
Injection Molding Analysis 2.0: analyze injection-molded parts and simulate filling
With this online tool you can analyze injection-molded parts directly from STEP models. Even before mold design, wall thicknesses, flow paths, part volume and basic manufacturability can be checked. The filling behavior of the part can then be examined.
Injection Molding Analysis 2.0 supports designers, mold makers and product developers in identifying critical areas early, evaluating changes to the part and optimizing the design for injection molding.
What is Injection Molding Analysis 2.0 used for?
In plastic parts, geometry, wall thickness, flow path, material and gate location significantly influence whether a cavity can be filled evenly and with acceptable pressure. Early analysis can help identify design weaknesses before toolmaking and series production.
Typical applications:
- Check injection-molded parts for manufacturability
- Analyze wall thickness and wall thickness variations
- Evaluate flow paths in the part
- Evaluate suitable gate areas
- Estimate filling time and required pressure
- Evaluate the temperature profile during filling
- Detect possible weld lines and air traps
- Estimate cooling and cycle times
- Optimize designs before toolmaking
Which analyses are available?
DFM-Check
The quick DFM check is used for the first assessment of the part's manufacturability. Wall thickness, flow path and part volume are analyzed, among other things. A first estimate of the required clamping force can also be made.
Filling simulation
The filling simulation examines how the polymer melt spreads through the part from the selected gate location. Important process variables such as filling time, pressure and temperature are evaluated. The analysis can also provide hints about critical filling areas, weld lines and possible air traps.
Process analysis
For a more advanced assessment, packing pressure, cooling time and the resulting cycle time can be taken into account in addition to the actual filling phase. This makes it possible to assess not only manufacturability but also the likely production process.
How does Injection Molding Analysis 2.0 work?
- Upload the plastic part STEP file
- Check the 3D model in the viewer
- Define the material and required process parameters
- Select the gate point on the 3D model
- Start the DFM check and inspect wall thicknesses and flow paths
- Run the filling simulation if needed
- Evaluate pressure, temperature, filling time and critical areas
- Adjust the design or process parameters if needed
Check the wall thickness of the injection-molded part
Wall thickness is one of the most important design parameters of an injection-molded part. Wall thicknesses that are too small can make complete filling difficult, while large or strongly varying wall thicknesses affect cooling time, material consumption and part quality.
The wall-thickness analysis shows the distribution directly on the 3D model and helps identify critical areas during design.
Analyze gate location and flow path
The gate location influences how the polymer melt spreads through the cavity. In the 3D viewer, a gate point can be selected on the part. Based on this, the flow paths and filling behavior are evaluated.
By comparing different positions, you can examine how the gate location affects the fill path, pressure requirement and possible critical areas.
What results are output?
- Part volume
- Wall thickness and wall-thickness distribution
- Flow path lengths
- Filling time
- Required filling pressure
- Temperature evolution
- Estimate clamping force
- Indications of weld lines
- Indications of possible air traps
- Cooling time
- Estimate cycle time
Material and process parameters
For the analysis, material properties and process parameters can be taken into account. This makes it possible to compare different plastics and processing conditions and examine their influence on filling behavior.
Generic material data serve as guiding engineering values and do not replace the binding material data of the respective plastic manufacturer.
Which development phase is the tool suitable for?
Injection Molding Analysis 2.0 is especially useful during design and before final tool release. In this phase, changes to wall thickness, geometry or gate concept can often still be made with relatively little effort.
The tool is therefore suitable for preliminary analyses, variant comparisons and the design optimization of plastic parts. For final tool and series approval, more detailed calculations and expert evaluation are required depending on the part and application.
Current limitations
- maximum file size of 50 MB per STEP file
- generic material data are not binding manufacturer data
- Simulation results are technical calculation and assessment values
- complex parts may require a more detailed process simulation
- Review results professionally before toolmaking and production decisions
Privacy and data processing
For the analysis, the STEP file is temporarily transferred to the server and processed exclusively for the selected calculations. The uploaded data are automatically deleted after processing is complete.
It is recommended not to upload confidential or safety-critical CAD models unless this is absolutely necessary.
Further information can be found in our privacy policy.