We perform a complete mold flow analysis on every new injection mold we build. The mold flow software today is very accurate at predicting potential injection molding problems and bring benefits. By optimizing the cooling circuitry valuable cycle time can be reduced. Warpage data can be used to play critical features steel safe or modify the part model by adding windage. Injection molders and mold makers who neglect this important step are losing a lot of potential profit in lost time and wasted material.

A few of the major benefits that I have found with Moldflow are:

1. Identifying "Knit Lines" that may be problematic.

2. Observing the dynamic mold flow fill to better understand the way the resin fills the cavity and sometimes capturing air/gas within the final fill stages within the major parting line (sometimes called "Race tracking"). Adjustments in gate location(s) and/or adding vented ejector pin(s) in specific predicted locations can eliminate long term issues.

3. Manipulation of Gate(s) locations will serve to establish lower residual stress patterns and potential warpage in the molded plastic part.

4. Fill times can be reduced with optimum gate size and locations.

5. Optimization of P/L venting placement (most tools I've seen over the years have had P/L vents placed along the flow length of the part, whereas, once the material flow passes the vent it is blocked and no longer functions.