The Magazine of Choice for Plastics Professionals › uploads › 1 › 3 › 5 › 8 › 13585698 › ...The Magazine of Choice for Plastics Professionals industry education Viscount

ff rroonntt

Vol. 2, Issue 1 2002

case studies

www.moldflow.com

March 2002

T h e M a g a z i n e o f C h o i c e f o r P l a s t i c s P r o f e s s i o n a l s

industry education

Viscount Plastics

Swift Technologies

BIMS Seminars Take a Non-Traditional Approach

Working Smarter with Web-Based Training

Penn State Erie — The Impact Players of Tomorrow

It was said that it couldn't be done: Start from nothing, end with a molded part, finish in a day.

Yet, at NPE 2000, this was done not once, but five times. Five days, five different part designs, five different productionmolds, thousands of injected parts produced, live on the showfloor. The software of choice, and the only software needed forthe “Mold-in-a-Day” RUSH Technology team: PPrroo//EENNGGIINNEEEERR®®.

Pro/ENGINEER is the only choice to tackle the whole job, takingindustrial design concepts to completed toolpaths with notranslations, while permitting last-minute no-penalty changes.

Art to part at breakneck speed.

To learn more about how you can significantly improve your timeto market visit www.ptc.com/products/function/tool_die.htm orkeyword search rruusshh.

© 2

001

Para

met

ric

Tech

no

log

y C

orp

ora

tio

n. A

ll ri

gh

ts r

eser

ved

. PTC

, Pro

/EN

GIN

EER

an

dth

e PT

C lo

go

are

tra

dem

arks

or

reg

iste

red

tra

dem

arks

of

Para

met

ric

Tech

no

log

y C

orp

ora

tio

n.

PPrroo//EENNGGIINNEEEERR®® MMoollddSShhoopp™™:: EEnnggiinneeeerreedd ffoorr IInnnnoovvaattiioonn iinn tthhee MMoolldd IInndduussttrryy

AArrtt ttoo PPaarrtt aatt BBrreeaakknneecckk SSppeeeedd

Flow ff rr oo nn tt

contentsfocus onIntroducing Moldflow Plastics Advisers 6.0

cover storyThe Benefits of Process Monitoring in the Real World

ccoovveerr ssttoorryy 1177

Manufacturingin the RealWorld

For more information, contact us at:Tel: 508-358-5848Fax: 508-358-5868Web: www.moldflow.comEmail: [email protected]: 430 Boston Post Road

Wayland, MA 01778Editor: Laura CarrabineCopy Editor: Marcia SwanDesigner: Joanna Gavriel

How to Advertise

Contact Marcia Swan at 607-257-4280, ext. 467for rates and availability, or go to our Web site atwww.moldflow.com and click on the Flowfronticon, then click How to Advertise. Here you candownload a PDF file that contains our insertionorder and rates.

ffooccuuss oonn 55

Introducing MPA6.0

from the editor

tips and techniques

the executive view

the analyst says

user reviewEarly Analysis Reduces Lead

Times for Sydney Olympics

Athletes’ Beds

professional developmentDr. Vito Leo Successfully

Launches BIMS-Seminars

Working Smarter with

Web-Based Training

real world successSwift Technologies Applies

Moldflow Plastics Advisers to

Every Job

the polymer pagesCRIMS, the Benchmark Standard

for Shrinkage Prediction

learning curvesPenn State Erie: Teaching the

Plastic Industry’s “Impact

Players” of Tomorrow

design & moldingMedical Device Design

Challenges

what’s newMoldflow Extends the

Capabilities of MPI/Gas in

Moldflow Plastics Insight 3.0

FEATURES5

17

8

11

14

21

24

26

27

4

9

16

29

COLUMNS

DEPARTMENTS

©2002 Moldflow Corporation. All rights reserved. Flowfront is a bi-yearly publication of Moldflow Corporation. Moldflow, Moldflow Plastics Advisers, MPA,Moldflow Plastics Insight, MPI, Moldflow Plastics Xpert, MPX, Shotscope and EZ-Track are trademarks or registered trademarks of Moldflow Corporation. All othertrademarks are properties of their respective holders.

FREE ReportReveals the Best Kept Secrets

of In-Plant TrainingIf you’re considering the implementation of an in-

plant training program, one thing matters. Will itimprove your bottom line by giving you a competitiveadvantage now as well as in the future?

Recent breakthroughs in training technology aremaking this possible like never before. This newtechnology, developed by A. Routsis Associates, takesfull advantage of multimedia while using the latest inlearning technology. Utilizing this powerfulcombination results in shorter training times and higheremployee retention rates.

Over 100 Interactive Training titles, including moldmaking and mold design, injection molding technology& plastic part design.

For a FREE copy of The Best Kept Secrets of In-House Training and the latest issue of Plastics TrainingReview contact:

A. Routsis Associates, Inc.275 Donohue Rd, Suite 14 ▼ Dracut, MA 01826

Tel:(978) 957-0700 ▼ Fax:(978) 957-1860www.traininteractive.com

from the editor

4Flow front Vol . 2 I ssue 1 www.moldflow.com

Finally! Refreshing news

Recently, I attended the Daratech Summit 2002 conference in New York City. It was wellattended by technology leaders who now tout product lifecycle management (PLM) products andstrategies. Whether you buy into this latest buzzword or not, I came away feeling much moreconfident about the state of our industry and the state of our economy. The reason? Presentations,in particular, by Bernard Charlès of Dassault Systemes, Carol Bartz of Autodesk, and Tony Affusoof EDS. They gave positive, uplifting commentaries about industry growth, profits, and newtechnologies that are helping to spur their businesses, and, more importantly, provide customerswith innovative solutions to develop new products at record-breaking speed while reducing manufacturing costs andexpensive prototypes. This is extraordinary good news for everyone served by these companies, their suppliers, and partners.

While the worldwide technology marketplace has experienced a rough road over the last 18 months, these three industryleaders envision a brighter future for everyone as we move forward into 2002 and beyond. In addition, Mark Goldstein,president and CEO of HKS, developer of worldclass ABAQUS CAE software and a Moldflow partner, announced hisresolve at Daratech Summit 2002 to "take the wraps off" the company's quiet history. He provided statistics that showedstellar growth since the company's 1978 inception, as well as its recent news to partner with LMS and Dassault Systemes.More collaboration among vendors can only make the user workplace a friendlier, easier-to-innovate environment.

Even though Moldflow was not part of the Daratech Summit 2002 event, its latest news is just as encouraging. Companypresident and CEO Marc Dulude recently reported that the company's financial results for the second quarter of fiscal 2002were encouraging. He said, "We entered this quarter with good visibility into our business and were able to close a highpercentage of our sales opportunities. We were particularly pleased with the order flow for our Manufacturing Solutionsproducts, which comprised 17% of our software product revenues this quarter. These products, which yield significant andrapid returns, present a compelling value proposition to injection molders who are seeking strategic advantages to remaincompetitive during this time of economic uncertainty."

In addition, this week financial guru Alan Greenspan announced that the global economy is beginning to turn around. Imust believe that these technological and financial events and others to come will help our industry start to climb back tomarket profitability, calmer, more confident investors, and a bullish Wall Street. And, while it may be a little too early totoast to a new economy, I am confident that we can all rest easier, anticipate a brighter future, and confidently begin toconsider reinvesting in profitable companies. We salute development and management teams everywhere that arecommitted to generating new products that exceed customer expectations as the economy moves back to a more stable,energetic state.

Certainly, Moldflow is taking the lead among leading software providers. This issue reveals how the company is offeringinnovative training and certification classes to help users become more productive and marketable. We describe thecompany's newest technologies, as well as detail customer testimonials as more competitive enterprises as a result ofimplementing the company's software. In addition, we believe in education - teaching university students the merits ofusing state of the art plastic simulation software as it relates to real-world applications before they enter the workplace. Casein point: we think you'll be impressed reading how Penn State University is using Moldflow technology in the classroom asan integral teaching tool. Students there are enthusiastic users who are realizing that the software will help them securepromising jobs that build upon lessons learned in the classroom.

Again, please send us your Moldflow software tips and techniques, questions, comments, and offers to act as customertestimonials. Send them to me at [email protected]. I look forward to meeting with you at the 2002International Moldflow User Group Conference as this issue unfolds.

Best Regards,

Laura CarrabineEditor


Focuson

Introducing Moldflow PlasticsAdvisers 6.0

Introduction

Since its launch in 1997, the MoldflowPlastics Advisers™ product line hasrevolutionized the way that designerscheck their plastic part designs formanufacturability. The upcoming releaseof Moldflow Plastics Advisers 6.0 (MPA™

6.0) provides users with significant newfeatures and enhancements forcollaborating with other users, providingproduct usage feedback in order to partnermore closely with Moldflow, andincreasing productivity. As part ofMoldflow's commitment to provideongoing value to the existing MPAcustomer base, most of the new features inMPA 6.0 are a direct result of customerenhancement requests.

This article describes in detail new MPA6.0 features and enhancements, including:

❒ Moldflow Community Center —a suite of Web-centric tools that foster interaction with other MPA users and Moldflow Corporation.

❒ Automated Product Usage Feedback— an automatic method for submitting valuable product usage information to Moldflow to aid in creating better products.

❒ Gate Optimization Analysis —used to determine optimized gate dimensions.

❒ Automated gate design advice.

❒ Modeling tools and results visualization enhancements — including expanded automatic runner generation and geometry mirror capabilities, as well as a powerful results comparison feature.

❒ Enhanced CAD interfaces — MPA 6.0 supports Moldflow Design Link 3.0, which allows the direct import of native Pro/ENGINEER® part files, as well as Parasolid, STEP and IGES file formats.

Moldflow CommunityCenter

The driving philosophy behind the newMoldflow Community Center is that a“whole product” implemented by the useris more than just a box of software. Just asimportant are elements such as service andsupport, market and industry education,product education, strategic partners, anda sense of community in which peoplework together to solve a commonproblem. Guided by this philosophy, theMoldflow Community Center has beendeveloped to host a set of Web-centrictools that foster interaction andcollaboration among MPA users and withMoldflow Corporation. Activemaintenance users can access theMoldflow Community Center directlyfrom within MPA 6.0 using embeddedWeb browser technology. The followingtools are available at the MoldflowCommunity Center:

Discussion Group

Communicate with other MPA users,exchange ideas and tips, discuss issues, askquestions, and obtain answers. Thediscussion group facilitates a mechanismfor users to gather collective knowledgeand solve common problems.

Report Product Issues

MPA 6.0 streamlines the process of issuereporting by allowing users to report issuesdirectly from within the product. AMoldflow customer support engineer willreview the issue, take appropriate action,and update the customer on the problem-solving status.

Suggest ProductEnhancements

MPA 6.0 users can have a say infuture Moldflow softwaredevelopment by submittingenhancement requests to help usdrive future product development.

Frequently Asked Questions(FAQ's), Known Bugs List,Hints & Tips

Stay up-to-date by reviewing FAQ'sand the Known Bugs List. Also,become more productive by readinghints and tips posted by Moldflow

support engineers and fellow users.

Direct Access to Knowledge Zone

Moldflow's Knowledge Zone is a vastinformation warehouse containing awealth of knowledge on an array of topicsfrom plastics product conceptual design tomanufacturing. Tap into the KnowledgeZone content by linking to its Web site orperform a search to navigate directly to thetopic of interest.

Product Revision Download

This feature allows users to access the mostrecent patch releases, ensuring they areusing the latest technology.

Access Training Resources

View all training resources available foryour Moldflow products and sign up forupcoming training sessions. Trainingelevates users to become more productiveand maximizes their return on investmentin Moldflow software.

File Exchange Area

This is a common file storage/downloadarea for useful files such as commonrunner layouts, standard runner sizes, etc.

By Murali Anna-Reddy, Moldflow Corporation

News Flash

The news flash relays important and time-sensitive information about MPA, theMoldflow Community Center, and anyrelevant current events.

Automated ProductPerformance and UsageLogging

Moldflow has kept abreast of customerexpectations through a variety of methodsincluding user surveys and user groupmeetings to ensure that we are developingtechnology that adds value to ourcustomers' processes. We realize that oneof the keys to meeting our customers'expectations and developing betterproducts lies in the continuousmonitoring and analysis of productperformance and product usage.

With that in mind, MPA 6.0 is configuredto log product performance and productusage information and automatically sendthat information to MoldflowCorporation periodically. Informationcollected in these logs will allow us toinvestigate product usage patterns andidentify areas for product improvements.Ultimately, this process will provide anopportunity for MPA users to moreactively partner with Moldflow and helpus create better products to meet theirneeds.

The product usage information will beautomatically logged and uploaded toMoldflow Corporation through a secureFTP connection. It is important to notethat no proprietary information isgathered in this process, nor will the databe shared with anyone outside ofMoldflow Corporation.

Gate Design OptimizationTools

Troubleshooting and optimizing the gatedesign remain key challenges for many

mold makers today. To help alleviate thisproblem, two powerful tools areintroduced in MPA 6.0. The first of thesetools is the ability to run an automaticgate sizing analysis, which estimates the

best gate dimensions and automaticallyupdates the model with the calculateddimensions. Automating the process ofoptimizing gate dimensions means molddesigners have one less aspect to worryabout in their mold design.

The second optimization tool is theautomated gate design advice, whichremoves the guesswork involved introubleshooting gate-related problems.Users are provided with gate-specificadvice, allowing them to drill down ateach gate and obtain specific advice ontroubleshooting and solving gate designproblems.

Moldflow Mold AdviserModeling Enhancements

From a geometry model standpoint, amajor focus of MPA 6.0 is to introduceseveral enhancements in Moldflow MoldAdviser that can drastically reduce thetime spent in modeling, resulting insignificant productivity gains.

In increasing the number of gate typessupported, two new gate cross sections —half-round and trapezoidal — have beenadded to the database of available gatetypes. The half-round gate can be used to

model gates that are part of an ejector pinor an insert. The trapezoidal gate allowsfor easier modeling of typical edge, fan,and tab gates.

Within MPA 6.0, it is possible to performan analysis with only the gate(s) attachedto a part cavity model. This is extremelyuseful when several gate design analysisiterations are planned and analyzing acomplete multi-cavity layout with the feedsystem attached would be timeconsuming. Once an optimized gatedesign is determined, the sprue and therunners can be added easily to completethe feed system.

With MPA 6.0, users can automaticallycreate runners in three-plate molds, whicheliminates the tedious task of manuallycreating runners for standard three-platemold layouts. Another useful modelingenhancement is the facility to create amirror copy of a part cavity model. Withthis feature, MPA users no longer need todepend on their CAD system forimporting mirrored components, andtherefore, separate CAD models foranalysis purposes. The ability to easily editrunner system lengths makes it easy forusers to decrease modeling time and reusepreviously created runner system layouts.Finally, it is also possible for MoldflowMold Adviser users to create a library ofstandard geometric sizes for use whenmodeling sprues, runners, and gates.

Results Comparison Tools

MPA 6.0 includes a powerful resultscomparison utility for simultaneouslycomparing analysis results from two or


It is increasingly more important to stay wellconnected with our customers to ensure that weare developing technology that adds value toour customers’ processes.

Focuson


more models. Users simply open two (ormore) models with results, thensynchronize the window displays and theresults plot scales. Users can thensimultaneously investigate the models andresults. This feature helps users to betterinterpret results and quickly identifyoptimized combinations of part geometry,material selection, gate locations, andprocessing conditions.

Enhanced CAD Interfacesand CAD Integrations

Moldflow Design Link 3.0 (MDL 3.0) iscompletely integrated with MPA 6.0.Moldflow Design Link 3.0 provides ageometry data translation interfacebetween Moldflow Plastics Advisers andleading CAD systems using standard fileformats such as IGES, STEP, andParasolid, as well as allowing direct importof native Pro/ENGINEER® part files.

The MPA CAD-integrated versions havebeen updated to support the latest productreleases from the world's leading CADcompanies, including SolidWorks2001Plus, Solid Edge 11.0, SolidDesigner2001, and Mechanical Desktop 6.0. Also,new in MPA 6.0 is an integration withAutodesk Inventor 5.0.

Other Key Enhancements

The material database has been redesignedwith an emphasis on ease of use.Commonly used materials are saved to aseparate list to expedite material selection.Search criteria can be customized to searchby virtually every material property in thedatabase. Lastly, viscosity, PVT, and otherrelevant material data can be quickly andeasily plotted.

Enhancements to the Report Wizard focuson increasing the efficiency of the reportcreation process and the effectiveness ofthe reports created. Users can now createreports that include results from severalanalyses. In addition, reports can becustomized in many different ways,including turning on/off features,selecting view bookmarks, adjusting imagesizes, choosing font size, and arranging theorder of results.

MPA users who wish to perform more in-depth analyses can export their data usingthe Moldflow Plastics Insight 3.0 (MPI3.0) study file format. All pertinentmodel, material, and analysis informationwill be exported from MPA, eliminatingthe need for redundant actions in the MPI3.0 environment.

Analyses can be set up using logicalsequences to eliminate the need formanually launching individual analyses.For example, a Plastic Flow + Sink Mark +Cooling Quality Analysis sequence wouldlaunch the three analyses sequentiallywithout any additional user intervention.

MPA 6.0 also includes a new, compressedcommon file format for both MoldflowPart Adviser and Moldflow Mold Adviser,reducing disk space storage requirements.

New License Manager

The Sentinel License Manager, fromRainbow Technologies, replaces Elan asthe License Manager for MPA 6.0. Newlicense keys are required to use MPA 6.0and can be obtained by completing theproduct registration. A new CommuterLicense feature is available in Sentinel,which allows users to check out a licensefrom a license server for up to 30 days, anduse the license remotely, such as on alaptop computer. This feature is availableonly on PC systems and does require afloating license.

Update on SupportedHardware

PC users can now choose either Intel orAMD processors, as support of the AMDAthlon processor has been added. Alsonew is support of Microsoft's WindowsXP operating system.

The complete list of officially supportedhardware platforms and operating systemsincludes Microsoft Windows 2000,Windows ME, Windows XP andWindows NT, Sun Solaris 2.8, HP-UX11.0, SGI Irix 6.5, and IBM AIX 4.3.5.

Conclusion

MPA 6.0 contains significant new featuresand enhancements for increasingproductivity, collaborating with otherusers, and providing product usagefeedback in order to partner more closelywith Moldflow.

Focuson

For the latest information on MoldflowPlastics Advisers and all of Moldflow'sproduct and services, visit our Web sitewww.moldflow.com.

user review

Background

Dunlop Bedding, a division of Pacific Dunlop and the largestAustralian manufacturer of beds, was the provider of 24,000 bedsthat made their debut at the Sydney 2000 Olympic Gamesathletes' village. These "bunkable" beds were designed for use assingle beds or stacked to form bunks, with the option of extendingthe length of the beds by 300mm for use by the taller athletes. Inaddition to meeting the functional and structural requirements,Dunlop Bedding was also looking for a fresh, modern shape andcolor. Dunlop Bedding decided to manufacture the bed frames inpowder-coated steel and the bedhead panels in translucent plasticwith a choice of several bright colors.

Viscount Plastics is a member of the Pacifica Group and thelargest injection molding company in Australia. Viscount Plastics(Victoria) was chosen by Dunlop Bedding to project manage thedesign and manufacture of tooling and to produce 48,000bedhead panels for these beds. Viscount recommendedpolypropylene homopolymer as the material for the bedheadpanels, as it met the requirements for safety, aesthetics, lowweight, low maintenance, ease of assembly, and cost effectiveness.

The Project

As the translucent bedhead panel is a highly visual part, a criticalrequirement was that there could be no visible defects or warpage."We have utilized the analysis expertise of Moldflow's consultantsfor a number of years now, with filling, cooling, and warpageanalyses being important tools in the part and mold design phases.We decided that the ability to verify and optimize tool andproduct designs early in this project should help us to reduce leadtime to manufacture, avoid start up problems, and reduce rejectrates," said Mr. Vadim Gershon, Product Development Manager,Viscount Plastics. In thisproject, Moldflow'sconsultants wereemployed at the productdesign stage in order tooptimize the part and tooldesign and to verify cycletime and processingconditions. "We wanted toensure that we couldreduce lead times of thefirst acceptable samples, sothat Dunlop Beddingwould have enough timeto tune the othercomponents to fit thebedhead (if necessary),and supply beds in timefor the Olympic Games,"said Mr. Gershon.

Moldflow Part Adviser software was used to verify the gate designand location suggested by Viscount and to assess the fill pattern."The Part Adviser analysis confirmed that the area of the part atthe end of the longest flow path would fill for the proposed cavitylayout and wall thickness with the choice of polymer and gatelocation," said Mr. Derek Hain, Senior Consultant, Moldflow.The original design of the bedhead called for a three-pieceassembly. Viscount's engineering team suggested the use of slidingcores driven by hydraulic cylinders, which would allow a one-piece bedhead panel to be manufactured. Several iterative analyseswere undertaken, and itwas found that the panelscould be produced as asingle part instead of threeseparate components.

Further analyses usingMoldflow’s MPI/Flow,MPI/Cool and MPI/Warpwere undertaken to verifycycle times and to ensurethe design specificationsfor dimensional tolerance,aesthetics, and negligiblewarpage were met.

"MPI/Cool was used toverify and optimizecooling line layouts andconfirm that theprocessing conditionssuggested by ViscountPlastics could be used," Mr. Hain said.

The results from MPI/Warp indicated that there would be verylittle warpage, as the fill pattern and the cooling lines had beenoptimized by then. "The predicted warpage was negligible andcould be further reduced with fine tuning of the injectionmolding machine settings and tool temperatures duringmanufacture," Mr. Hain added.

The Outcome

The initial mold trials showed that the actual cycle time was veryclose to that predicted by Moldflow's software, and the partsproduced had met design specifications. "Preliminary workconducted jointly by Viscount's engineering team and Moldflow,as well as excellent toolmaking by Centre Tooling, has allowed usto achieve a near-perfect part at the very first die trial. We haveprobably saved at least one tool rework and subsequent die trial,which could have cost us several thousand dollars and increasedlead time by up to 20 percent," said Mr. Gershon.

Early Analysis Reduces Lead Times forSydney Olympics Athletes' BedsBy Laura Carrabine, Editor


We want to help you work smarter and get up to speed faster with your Moldflow Plastics Insight (MPI) 3.0 software. Here arethree tips that will help you streamline your modeling tasks and transition quickly from previous versions of the software.

Find a complete list of Hints & Tips as well as answers to Frequently Asked Questions and other valuable information on theCustomer Resource Center (CRC) at www.moldflow.com.

tips & techniques

Work Smarter with Moldflow PlasticsInsight 3.0 By Matthew Jaworski, Moldflow Corporation

The default colors of MPI 3.0 beam elements have specific meanings.

Red -> Hot Runner

Green -> Cold Runner

Blue -> Cooling Channel

Yellow -> Baffle

Orange -> Bubbler

Beige -> Connector Hose

Did you know?

Stop by and visit AMD at the

Moldflow 2002

International User Conference March 17-19, in Boston, MA.

tips continued on next page

Import a model into MPI/Synergy, then select Mesh > MeshStatistics. Look under Intersection Details forinformation about Element Intersections and FullyOverlapping Elements. These are defects in the mesh thatyou will need to fix before running an analysis.

Select Mesh > Mesh Tools to access tools that will helpyou fix the defects. First, try the Auto fix tool, whichautomatically tries to fix overlaps and intersections. Don'tworry about the result, because the tool reports AspectRatio before and after - this will change only if the fixeddefect happens to be related to the minimum or maximumaspect ratio. Check Mesh Statistics again to see if Autofix solved your element problems.

If Auto fix did not fix all the defects, go back to MeshTools and select Global Merge. This tool merges nodeswithin a specified tolerance. Be careful if you leave thePreserve Fusion checkbox option blank! When checked(turned on), this option prevents nodes from being mergedif this would result in the removal of a side of a triangle.

Your next option is to display the overlapping elements andmanually fix the mesh. To display these elements, selectMesh > Overlapping Elements. On the dialog thatappears, you can select to display Overlaps, Intersectionsor both. Be sure to check the Place Results in DiagnosticLayer option.

Deselect all layers, so that only the Diagnostic Resultslayer is visible. Clicking on the Diagnostic Results layer tohighlight it, then select the Expand button. The Expandbutton grows the mesh around the highlighted layer by auser-defined level, in this case one. This feature is veryuseful to see what elements need to be fixed and the areaaround them.

Next zoom in on one particular area and use the center icon to center the view for ease of rotation.

There are many ways to fix overlaps and intersections. Inthis example, the problem element is protruding throughother mesh elements at a corner. We can select and deletethis element using Mesh Tools > Delete or simply by using

the select icon to select the element and clicking theDelete key on the keyboard.

TIP: To speed up the mesh editing process, turn the meshdiagnostics window off before using any Mesh Tools ordeleting elements. To do this, select Mesh > ShowDiagnostic or click in the MPI/Synergy graphics windowand click Ctrl + D. After the editing action is complete, youcan turn the diagnostic window on again by repeating theprocess.

Another common way to fix overlaps is to merge nodes.This is also accomplished using the Mesh Tools menu.Simply select the node you want to merge to and then thenode you want to be merged.

Use Mesh Tools > Purge Nodes to clean up anydisconnected nodes that may have been created during thecleanup operations.

Finally, review the Mesh Statistics to make sure the meshis defect free.


tips & techniques

Fixing Overlapping Elements


professional development

In March 2000, Professor Vito Leo, Ph.D. (Brussels, Belgium),established the Brussels Injection Molding Sessions (BIMS-Seminars) business. BIMS-Seminars provides seminars based onLeo's 20+ years' experience in the injection molding and plasticsindustry and what he says is a real need for non-traditionaltraining. His seminar called "Understanding Injection Molding ofThermoplastics — The Key to Optimum Plastics Part Design,"provides an explanation of the mechanics and physics behindplastic injection molding processes. Leo is a physicist by trainingand has extensive experience in polymer processing. He isparticularly active in the field of injection molding ofthermoplastics and the use of thermoplastic finite-elementnumerical simulation.

"During my career at Solvay asa Principal Scientist at theBrussels-based company," saysLeo, "I realized that there was areal need for a seminar thatthoroughly explains some verycomplex phenomenon in fairlysimple terms. People areextremely interested inattending this kind of seminar.It's not traditional injectionmolding training. It's not flowanalysis training. It's not puretheory. I really try to fill a gap.People have real problems everyday. How do they solve them?For many, it's been years sincethey graduated from theiruniversity. They may know a little bit about plastics, or they mayknow a lot. However, they don't have time to investigate rheologydetails and thermodynamics of polymers, crystallization and othercomplex issues."

"For me, there are clearly two very separate worlds when it comesto plastics professionals — those who make products but don'tknow physics fundamentals, and those who work in institutes oruniversities who are very interested in fundamental work orequations but don't know much about real life and real problemsin injection molding. So, my material fits between these twoentities," adds Leo.

As a result of this unique approach, Dr. Leo has attracted a diverserange of seminar attendees in the nearly two years he's been inbusiness. The seminars generally attract engineers, designers, andshop floor operators. However, university students and professorsattend them as well. "They all seem to take added value back totheir workplaces after a seminar," says Leo.

Each two-day BIMS-Seminar includes the use of MoldflowPlastics Insight (MPI) software to show MPI/Flow, MPI/Cool,MPI/Shrink, and MPI/Warp. "I always envisioned Moldflow aspart of the seminar because of its valued use over the years atSolvay," notes Leo. "The software is very useful to understand theprocess and the complex physics behind the analysis even thoughthe accuracy of some predictions is not always perfect. It's anextremely useful tool to assess, for instance, the relativeimportance of various contributions in the warpage trend youpredict with a given part."

Upon initiating his seminar business, Leo agreed not to use anySolvay resources or provide any proprietary Solvay information as

part of any BIMS seminar.He relies on MPI softwareto build examples toillustrate the ideas discussedat the seminar. To make sureattendees get useful practicalinformation, he asks knownMoldflow consultants(NKT Research inDenmark and Promold inFrance) to conduct anevening session based oncase stories at the end of thefirst training day.

The BIMS-Seminars offer acomplete description of thephysics behind injectionmolding. "I try to very

clearly show the relationship between material structure and theproblems users can encounter in injection molding. The seminarincludes extensive descriptions of amorphous, crystalline, filledand unfilled materials. In addition, I try to show how differentthese four classes of materials can behave with respect to filling,packing, shrinkage and warpage. The very different behavior ofglass-fiber-filled polymers compared to unfilled plastics is striking.Understanding the physics of these composite materials is the onlyway to design good parts and optimize the molding process," addsLeo.

He started his business with a private seminar at Nokia in Finlandwhere 30 attended — 20 designers and some of theirsubcontractors such as molders. Leo noted, "There was a lot ofpositive response as a result of that session. Some attendees said itwas the best seminar they ever attended in the field of injectionmolding."

BIMS completed six seminars in 2000 and seven in 2001. Manywere held in Scandinavia because of the strong mobile-phone

Dr. Vito Leo Successfully Launches BIMS-Seminars (Brussels Injection Molding Sessions)

By Laura Carrabine, Editor

industry interest and the training strategy as a whole in thenorthern European countries. A Danish institute agreed toorganize BIMS-Seminars and booked five events in Denmark sofar. BIMS-Seminars also organized two public seminars in Brusselsand Paris, and the first Italian seminar is scheduled for Spring2002. Overall, about 210 people have attended the seminars sofar.

Leo uses Moldflow during his seminars, not because he is tryingto sell the product, but because it's an extension of what he istrying to explain. "It's important to understand the assumptionson which any software package is based," says Leo. "A lot of thecommentary during the seminar is about the physics behind thepresent state of the art in simulation and why, under certaincircumstances, its capabilities may be limited. MPI is definitelyhelpful."

Leo says that he promotes extremely useful tools. He adds, "Assoon as you can understand the trends, and trace the physics as towhy you are experiencing a particular problem, then Moldflowwill be extremely useful. However, you need to understand thefundamentals first."

He relates that when he trained the staffers at a large Finnishcompany, some of those in attendance claimed they didn't reallywant to understand the software. They just wanted the software todo the work for them. "That is exactly what I am fighting against,"adds Leo. "The point I try to make is that you don't need to havea Ph.D. to understand the physics. But you might need someonewho has a Ph.D. to explain it to you. That's what these seminarsand I are all about."

As a result of the seminars at Nokia, Ericsson, and Bang &Olufsen, Leo says that designers have a much better understandingof the process. Flow analysts in these companies are usingMoldflow much more effectively. He says, "Since the seminar atEricsson, the company purchased a Moldflow license. I can't claimthat's because of my seminar. However, I am pretty convinced thatmy contribution must have been important because they cameaway from the seminar feeling that even though the software isn'tperfect, it will be very useful if you understand what you'redoing."

Apparently, people from all over Europe are happy to find all thisinformation within a single framework of one seminar presentedin a consistent way. Leo says the enthusiasm for more seminars inmore locations is growing despite a tight worldwide economy.

"As companies strive to work smarter in a challenging economicenvironment, they realize that doing better quality work up frontis very important," adds Leo. "Taking a serious approach toconducting simulation relates to reducing costs. Error-riddled andexpensive prototypes can be eliminated. I have first-handexperience with this phenomenon at Solvay using Moldflow."

"Recently, we experienced a slow-down in sales due to the generaleconomic trend. However, during that same timeframe, we had astrong increase in Moldflow simulation requests. So even thoughsales are lagging, people are busy preparing for the future, trying

to develop parts with better, more cost-effective designs at a fasterrate. And with the right training, Moldflow is a perfect way to dojust that."

While the seminars are a completely separate business from hiswork at Solvay, Leo says that the sessions work in favor of theplastics business as a whole. "I am just trying to increase the levelof understanding of the process that I believe can only benefit theindustry as a whole. Concurrent engineering will prevail when allthe involved parties speak the same language and share a commonknowledge base."



The first edition of Flowfront was a big hit atthe Office of Continuing EngineeringEducation at the University of Chicago atUrbana-Champaign. Professor JonathanDantzig of the Department of Mechanical andIndustrial Engineering will be using Flowfrontas part of his teaching materials. Notably,Professor Dantzig will use information in thefirst edition for teaching engineering studentsin his class called "Modeling in MaterialsProcessing," Mechanical Engineering 351,which began in the fall semester of 2001 andcontinues through the spring semester of2004.

At the school, engineering course lectures andcourse materials such as lecture notes,assigned readings, and handouts are madeavailable to registered University of Chicagostudents over the Internet. The school will bemaking Flowfront available to students as areference to the lead story "IntroducingMoldflow Plastics Insight 3.0.”

This unique approach to providingengineering students with valuable, real worldinformation about state-of-the-art technologywill help students gain insight to howinnovative software products andmethodologies are being used in productdevelopment today. This is a great example ofhow partnering industry with academia canenrich learning and strengthen undergraduateskills as preparation for real-world applicationof their knowledge and attaining excellentpositions after graduation.

NE

WS

F L A S H

For more information about BIMS-Seminars, to view acomplete list of customers to date, or to arrange a session, visitwww.bims-seminars.com.



A changing global economy has created new business cycles thatare demanding rapid action and increasingly efficient operations,requiring new business fundamentals and changing the waycompanies function and conduct business. These new businessfundamentals require that employees rapidly acquire new skill setsas the demand for trained professionals increases.

Even for the most experienced plastics professional, keepingcurrent on the latest technology can be a challenge. To remaincompetitive and succeed, proper and ongoing training is essential.Yet in today's business climate, organizations face the difficult taskof providing the necessary training amid the corporate calls fortighter budgets, hiring freezes, and doing more with fewerresources.

Given these parameters, Web-based training (WBT) has becomean increasingly popular new trend over the past several years. Inthe simplest sense, WBT is the use of Internet technologies todeliver training online. Recipients can receive training on a 24/7basis through browser access to the Internet, an extranet, or anintranet Web site, similar to common Web browsing activities.

This innovative delivery method provides high-speed access totraining content at the user's convenience and at the user's locale,eliminating the need for travel and time away from work. Theseself-paced, Web-based courses are accessible anytime andanywhere through the Internet. By providing a cohesive, virtualtraining environment, companies can overcome productiondowntime, temporary loss of resources, and travel costs.

When properly implemented, WBT utilizes the immediacy,flexibility, and richness of the medium to deliver a learningenvironment that complements traditional classroom and "hardcopy" delivery methods. Utilized as a foundation, WBT can evenimprove the overall effectiveness of instructor-led deliveryinstruction. Students can enroll in preliminary WBT courses, forinstance, to prepare for an advanced, instructor-led class. Inaddition, WBT offers extremely powerful and compellingadvantages for training employees in different locations. Globalcompanies may have users working at differing levels of expertise,on a variety of products, in multiple areas of the world. WBT isideally suited to address this type of worker training diversity.

At the Moldflow Center for Professional Development, we realizedthat our global customer base is benefiting from WBT in severalways:

❑ Eliminating time away from the workplace.

❑ Accessing training at convenient times, locations, and individual paces.

❑ Bolstering student confidence in Internet-based training andincreasing the likelihood of participating in additional WBT training sessions.

Moldflow's Web-based training courses are available through theEducation Zone at www.plasticszone.com.

Here you will find both Moldflow courses and courses from oureducation partner, Nypro Institute. Courses cover the latestreleases of Moldflow products, including Moldflow PlasticsInsight (MPI) 3.0 and Moldflow Mold Adviser, as well as severalgeneral courses on injection molding, materials and mold design.These Web-based courses provide Moldflow customers with awealth of plastics industry information.

Moldflow's Web-based training provides the ideal foundation fora blended training approach, complementing our traditionaltraining courses with the power and immediacy of onlinetechnology. This results in learning programs that provideincreased retention and greater effectiveness.

Oftentimes, a training course cannot be scheduled to meeteveryone's individual or departmental needs. In a manufacturingsetting, for instance, people who work in around-the-clock shiftsoften can only be removed from the line individually or in smallgroups. Web-based courses are an effective tool that can be usedthroughout a workday to train individuals without disrupting theproduction line. Unlike an instructor-led course, Web-basedcourses can be used at any time, in any place a computer isavailable.

Working Smarter with Web-Based TrainingBy Stephen Thompson, Moldflow Corporation

For more information about Moldflow's Web-based trainingcourses and other education services, please visit the EducationZone at www.plasticszone.com.


real world success

Swift Technologies Limited, a Cambridgeshire, England-basedmaterials technology company, provides the manufacturingindustry with unique solutions to traditional problems. Thecompany's Swiftool Rapid Manufacturing System aids in quicklyand economically producing plastic or polymer moldings. Thetechnology is based on a smart polymeric tooling medium thatfacilitates the blending of materials and manufacture of mold toolson site. The process involves application of pressure and vacuumto the Swiftool composite via purpose designed vacuum presses.

Swift Technologies' equipment varies in size from presses as smallas a household refrigerator to as large as a commercial truck. PaulShepheard is the company's technical director. He says SwiftTechnologies' (Swiftech) reason for doing business is to providetools as fast as possible.

"Traditionally, injection mold tools can take anywhere from oneweek to 16 weeks to manufacture," says Shepheard. "At Swiftech,we can fulfill orders in between one to 16 days. We are muchfaster. How? Our tooling system fast tracks the tool makingprocess." Engineers and designers are also finding better ways ofdoing their jobs, such as initiating very sound proactive practicesat the early stages of each job, including the use of Moldflow PartAdviser and Moldflow Mold Adviser software from MoldflowCorporation.

Swiftech operates two business models. One is designing andmarketing systems that enable molders to make injection moldtools very quickly. The other side of the business is using its ownequipment to make tools to generate customers' parts quickly."Obviously," adds Shepheard, "we wouldn't be able to make theparts if we didn't have the tools. We are in a unique position inthat we have all the equipment. When customers send us a 3D file,we are usually able to make those parts within a couple days byfirst making the tool and then making the parts."

However, in the first year of work, Shepheard and his colleaguesfound that their customers' designs were presenting them withproduction difficulties. "They didn't mean to," notes Shepheard."Unknowingly, they sent us part files that couldn't bemanufactured, and we didn't know it because we didn't design theparts. Back then, we went through our normal process. We'd makea tool and learn too late that the tool wouldn't satisfactorily makethe part. That's when we investigated Moldflow software. Wecouldn't afford to stay on the same costly path we were goingdown at the time."

Now Shepheard's team uses Moldflow software on every single filethat they receive. "Using Moldflow is an integral part of ourprocedures," says Shepheard. Swiftech operations can perform upto 20 Moldflow analyses per day. "Using Moldflow is part of ourproactive strategy to make sure that the part can actually be made.We don't even charge for running the simulations."

When a file comes through that shows design flaws, Swiftechreturns the file for customer redesign or for assistance fromShepheard and his team. Customers quickly learn that theirdesigns are not manufacturable early in the design process versuslater on when the tools have been machined and unable toproduce parts. "It doesn't happen often," notes Shepheard, "but atleast once or twice per week, we receive a file that we can't workwith."

He says another reason for using Moldflow on every single job isfor credibility. "Manufacturers have been making steel tools foryears and years," says Shepheard. "There are no questions aboutintegrity or quality, because people are used to tools being madeout of steel. However, with a new process like ours, when weturned jobs around and told customers that we couldn't maketheir parts, the customer started to question our expertise. So, weinvested in Moldflow to be able to show credible evidence thatmany issues are not our problems, but rather the customer's.Moldflow brings us confidence, credibility, and peace of mind."

Software benefits

Shepheard says that using Moldflow allows his team to locatedesign errors very quickly. "We didn't want to waste valuable timemanufacturing something that couldn't generate parts," addsShepheard. "The software automatically gives us the best injectionpoint and gate location. That was an absolute godsend to usbecause now, for every single job, we know for sure that all gatesare located in the optimized positions. Those two factors are themost important in our workflow."

"It works well for our customers, too. They know that we applybest practices to help them achieve their goal — obtaining parts.In the rare instances in which we fail, at least the failure arisesbefore steel has been cut — before the cost of the mistake can costcustomers five to ten times more than the actual job and take 10times longer. Moldflow allows us to interact with the design muchearlier, and if, there is a problem for whatever reason, now is thetime to do something about it."

Shepheard says that Moldflow has changed the way Swiftech doesbusiness. If the software didn't exist, Swiftech would not exist orwould be a significantly different organization. "The software hashad that big of an effect on the way we do business," notesShepheard.

Since investing in the software and hardware to run it, Shepheardsays the company has recouped its ROI many times over. "We'vemade about 400 tools now as a result of using Moldflow over thelast two years. We have made many more tools than could hope tobe achieved by a conventional toolmaker of comparable size andMoldflow has played a major part in our success," adds Shepheard.

Swift Technologies Applies MoldflowPlastics Advisers to Every Job


real world successSwiftech operators can simultaneously run approximately 12customer file simulations. Files are downloaded as STL, IGES, ornative CAD formats. The process uses STL files in two ways —one for Moldflow simulations and one for making patterns forgenerating tools. Shepheard says, "When a customer sends a partfile, we run the Moldflow analysis on it. If it's okay, we build thepart using stereolithography equipment to make a pattern. Wethen fabricate the tool around the pattern."

When it came time for Swiftech to investigate plastic simulationsoftware, Shepheard did some research on the Internet. "Moldflowhas an excellent reputation in this arena," notes Shepheard. "Wewere overwhelmed by the level of confidence that we heard fromcolleagues who were using the technology. Soon after, we saw ademonstration of the products and became a customer." That wastwo years ago.

Learning curve

Shepheard says that to really become proficient using the softwaretakes about four weeks. "For many other software packages,training and proficiency take upward of 12 to 16 weeks," addsShepheard. "Moldflow Part Adviser and Moldflow Mold Adviserare so simple to understand. While the packages are sophisticatedsoftware, they are at the same time easy to learn and easy to use."Several Swiftech engineers attended training at Moldflow's UK-based offices.

"Since we do run so many Moldflow analyses per day, we havebeen able to build up a level of knowledge and understanding

about the software. We like that it works with precision andreliability," adds Shepheard.

When Swiftech first installed the software, Shepheard and histeam tested the product by "feeding it" a design that had giventhem problems in the past with regard to gate locations. "TheMoldflow analysis showed that we shouldn't have gated the partthe way we did. We were so pleased that the software investigatedprecisely what didn't work. That gave us good feelings about howit would treat files for us correctly in the future. That was a goodinitial test. We knew we had struggled in the past with troubleddesigns and experienced the headaches they cause internally.Moldflow has helped eliminate all those long, arduous hours forus."

DO YOU HAVE A STORY TO TELL?

If so, we want to hear from you. To submitarticles, case studies, or user reviews of anyMoldflow technology, please contact Laura

Carrabine at [email protected] call +1 440 247 8653.

For more information about Swift Technologies Limited, visitwww.swiftech.co.uk. For more information about MoldflowPlastics Advisers (MPA) software, visit www.moldflow.com.

John McEleney, president and CEO ofSolidWorks, offers some thoughts onhow businesses should perceive thepresent economic situation and sometips on weathering the storm.

First of all, get a sense of perspective.The world is not ending. Workers andmanagement should take a deepbreath and realize that civilizationshave been around for millennia. Thinkabout it. We have endured centuriesfilled with upheaval and newdiscoveries. Be assured that there willbe a tomorrow and business will betransacted. As soon as people ridthemselves of fear, the black cloud willlift, and they will be in a much betterstate to be productive.

Second, focus on fundamentals. Whentimes are good, companies try toaccomplish as much as possible.However, when times are tough,people should focus on thefundamentals because they don't havethe extra cycles, extra capital, or theextra personnel to achieve all that theywould like to do. In addition,determine your company's raisond'être. Ask, "What do we do well?"and "What are customers willing topay for?" Regard this time as anopportunity to refocus.

To do so, determine your competition'sposition in the market space and whatyou can do to gain a competitiveadvantage. This is the point where youneed to tighten the belt one more

notch and continue to makeinvestments, even when times aretough. It's one sure way to gain thecompetitive advantage. Because whenthe economy begins to turn around,companies will find themselves in oneof three scenarios: either havinggained marketshare, maintainedmarketshare, or lost marketshare. Ithink most people in these marketshope to be able to maintainmarketshare. That's the wrongmentality. Companies must regard thistime as an opportunity to gain acompetitive edge. Be aggressive, evennow, to do whatever it takes to remaina winner. Take advantage of theopportunities that change creates.

Third, set priorities. In the book The 7Habits of Highly Effective People,author Stephen R. Covey talks abouturgent versus important. In times liketoday, I think prioritization isimportant. Determine what efforts areurgent and which ones are important.Then, structure your thought processesand work activities to address theimportant issues that are urgent.

Fourth, use this lull in the action toeducate yourself and update yourworkplace. If your operation is usingdated technology, study up on what'soffered today and what best suitsyour needs. Invest and train your staffso that when the economy turnsaround, you will be in a much morecompetitive position to gainadditional marketshare.

Case in point: Recently while onvacation, I met a longtime AutoCADuser. Ironically, his company recentlypurchased some SolidWorks seats. Hetold me that the younger users relishedthe new technology and migrated to itwith gusto. However, the older userswere using the traditional 2D CADsystem and methodologies as a crutch.With business a little slow, we bothagreed that this was a terrificopportunity for him to force the

change-resistant users to improve theirskill sets. Undoubtedly, this is the timeto implement new technology andconduct training so that when eventsdo turn around, companies will be in acompetitive position and muchstronger.

Technology providers today arefocusing greater energy on formingcollaborative partnerships, both fordelivering the latest advancementsefficiently to end users and promotingtechnology education. For example,Solidworks works closely withMoldflow to deliver integratedsolutions for the injection moldingplastics industry. Further, Web-basedoptions abound, make it easier toacquire new technologies and thetraining necessary to use them to theirfullest potential.

A few years down the road, whenwe look back, I bet the winners outof this recession are going to becompanies that went the extra mile,made sound investments in peopleand technology, and updated theirproduct development environments.Companies that take these boldinitiatives will reap tremendousrewards.

Lastly, maintain a sense of optimism.The world is getting bigger every dayand it will continue to needtechnology. Tomorrow someone willlaunch a new innovation, a newproduct, a new service, or newtechnology that will allow us all to bemore efficient. There is always going tobe that next level of innovation. Let meremind you that in the late 1800s, somefolks wanted to close the US PatentOffice because they thought thateverything that could be invented hadbeen. They were so wrong.

Working Smarter in a Tight EconomyBy John McEleney, President and CEO, SolidWorks

the executive view



ccoovvee rr ss ttoo rr yy

You cannot manage what you cannotmeasure. These words ring true for alltypes of companies across all types ofindustries. Imagine a gas station thatwas not measuring and tracking theamount of gasoline it distributed, or anenergy company that was notmonitoring the amount of energyproduced versus consumerrequirements, or a soft drink producerthat did not measure how long it takes tofill and package 500,000 bottles of itsproduct. These companies would haveno idea of when they were going to runout of gasoline, energy, or soft drink.Beyond that, they would not be able tomanage and grow their respectivecompanies because they were notmeasuring key performance indicatorsthat are fundamental to their businessoperations. Although it is hard tobelieve, today there are multitudes ofcompanies that do not measure keybusiness performance indicators, and theprice they pay is lost marketopportunity, labor productivity losses,and costs associated with manufacturinginefficiencies and unscheduledproduction downtime.

Not so for one innovative US-basedinjection molder, Vision Plastics, whouses the Moldflow Shotscope® process monitoring and analysissystem to measure and track key injection molding parameters,allowing employees to work smarter and more productively andgive their company a strategic competitive advantage. TheMoldflow Shotscope process monitoring and analysis system is acomprehensive product suite which collects critical data in realtime injection molding machines on the factory floor, thenrecords, analyzes, reports, and allows access to the information foruse in critical decision making. This article discusses how VisionPlastics has implemented Moldflow's Shotscope system to

monitor its injection molding process and the value derived frommeasuring what it has to manage in order to control and grow itsbusiness.

Eliminating Guesswork and Downtimewith Shotscope

Vision Plastics, Inc. started out in 1988 in Tualatin, Oregon, USAwith five molding presses and five employees. Today, the companyis relocated in a modern facility in Wilsonville, OR that housesmore than 38 machines and 150 employees. Vision Plastics is ISO

The Benefits of ProcessMonitoring in the

Real WorldBy Peter Rucinski, Moldflow Corporation

ccoovvee rr ss ttoo rr yy


9002 certified and one of the most highly regarded custominjection molding companies in the Pacific Northwest.

Today, Vision Plastics utilizes the Shotscope process monitoringand analysis system from Moldflow to assure that the very bestparts are being manufactured. This system, installed directly oneach molding machine, is a real-time program designed to capturea picture of each injection shot through predeterminedparameters. The data collected is available for review through anumber of display screens. Shotscope provides shot profiles,statistical process control trend charts, shot-to-shot comparisons,and a number of other displays. Each molding press is equippedwith an analyzer to capture the data and with a remote screen todisplay that data.

Each injection molding job has a set of predetermined parametersthat are input into the Shotscope system. Should any of theparameters move outside the control limits, the machine alarmsand highlights the discrepancy for immediate appropriate actionby the mold technician.

Any changes to the established molding processes that might benecessary are well documented through a Cause and Effect system.This closed-loop system identifies the root cause of anydiscrepancies in the process and documents changes that are madeto the injection molding machine settings to bring the operationback within the pre-set limits.

Mike Olson is Vision Plastics' Shotscope coordinator. It's his jobto keep all 26 Shotscope-based plastic injection molding machinesrunning at peak performance. "Shotscope generates profiles oroverlays of what the machine is doing internally at all times," saysOlson. "I save the overlays as references and as historical data. Ican pull any overlay up at any time and lay it on top of another tosee if there is any variation in the process. The overlays tell us if themachine is varying from shot to shot, showing inconsistency."

When Olson first joined Vision Plastics several years ago, thecompany was not actively using Shotscope. "We used it once ortwice but that was only because one particular customer wantedcavity pressure and mold temperatures from every shot. Once wemade the run, we downloaded the data to a diskette and sent it tothem with the parts. At that time, that was the extent of Shotscopeuse here."

At that time, Olson approached the company owner to find outwhy. "We used Shotscope at my previous place of employmentand the software was considered a valuable tool. I volunteered to

get the system up and running at Vision and we have been usingit ever since to its full potential." Shotscope monitors 26machines, although the software can monitor up to 32 machinesat once. Olson installed the Windows version of the software inAugust of 1997.

Shotscope Benefits

The software provides a graphical overview of the Vision Plasticsshop floor. Different colored icons depicts each machine. Grayicons depict machines with no communication between themachine and Shotscope. If the machine is not running, then theicon is red. A yellow icon represents an operating machine that hasexceeded one or more parameters. "Yellow signals me toinvestigate what is causing the machine to go beyond our setparameters," says Olson. A green icon indicates a machine that isrunning within all parameters.

"Anytime something goes wrong, I canquickly single out which machine needsattention," adds Olson. "Usually a quickadjustment or two is all that is needed andwe are back in business. Shotscope saves atremendous amount of time. Traditionally, itwould take several technicians and a lot oftime on the shop floor trying to figure outthe problem and how to remedy thesituation. Shotscope eliminates all thatguesswork and down time."

Recently, Moldflow engineers from the company's Oregon andAustralia-based offices visited Olson. I gave them a tour of thefacility and showed them how I use Shotscope. I made somesuggestions as to what I would like to see added to the next versionof the software such as pop up windows that give the userinformation about what the machine is doing. They seemed verypleased with the recommendations that we provided," says Olson.

During the visit with Moldflow, a Vision Plastics technician madean adjustment to one of the molding machines without confidingwith Olson or Shotscope. The adjustment caused a yellow icon toappear on Olson's monitor, indicating the highlighted machine's

"We used Shotscope at my previous place ofemployment and the software was considered avaluable tool. I volunteered to get the system upand running at Vision and we have been using itever since to its full potential," said Olson.

process had been changed. Overlays were created to show beforeand after process profiles. Upon comparison, it was clear that thenew process would cause an unstable process from shot to shot —an out-of-control condition and questionable parts. Theinformation proved that the technician did not use Shotscope inhis decision making. The process was subsequently re-adjustedand the machine was brought back into a controlled condition.

Three overlays originate from a linear transducer that measuresthe positioning and velocity of the screw. A pressure transducerprovides pressure overlays. These profiles can be downloaded justseconds after the machine completes a shot and Shotscopeanalyzes the data. "After a few shots, I know pretty much what isgoing on with each machine's process. Whereas, out on the floor,it would take me 20-30 minutes to gather the same data," Olsonsays.

It can be busy at times. However, Olson says that once he and thetechnicians start the machine and a stable process is established,his work is nearly complete for the whole run of each particularmachine. He adds, "If a heater band goes out, Shotscope will alertme now before we start producing rejects. I can keep my limits sotight that if the size of a part changes as minutely as 1/1,000 of aninch, I will know about it. Or, if I lose temperature, Shotscopehighlights it and we can address the issue then, not when themachine stops making parts, or when it starts making burnedparts, or when one of the zones overheats. Shotscope keeps a closeeye on all those areas that could become potential problems.”

"In this competitive market, Shotscope is invaluable. It helpsVision Plastics remain a viable contender in the industry as aleading producer of high quality parts," Olson explains.

Conclusion

You cannot manage what you cannot measure. These words ringespecially true for injection molder Vision Plastics, who relies onMoldflow's Shotscope system to measure and track key businessperformance indicators so that they can control and grow theirbusiness profitably and with a significant competitive advantage.

Shotscope profileanalysis revealed thatthe press was fightingto hit the transferposition, resulting ininconsistent fill timeand hold time fromshot to shot.

After the shot sizewas decreased, astable process wasachieved.

Shotscope resultsshowed that the presswas not holding asteady cushion length.Upon investigation,it was discovered thatthe machine's checkrings needed to bereplaced.

After check ringreplacement,Shotscope verifiedthat the machineperformed asexpected.

Visit the Education Zone to ... ... Get Moldflow Software Training! ... Get Moldflow Software User Certification! ... Participate in a Moldflow Web Seminar!

www. plasticszone.com

To learn more about Moldflow's Shotscope product, visitwww.moldflow.com. To learn more about Vision Plastics, visitwww.visionplastics.com


Do you know what job your machine is currently running? Is it running that job at its peak efficiency?What are the optimal settings on this machine for this specific job? This is information you need to knowwhen producing your parts, but you don’t have to carry that burden on your back!

Moldflow Manufacturing Solutions products can answer all of these questions for you. Whether you are a small,custom injection molder or a large multi-national corporation, our products will enable you to:

❒❒ Collect critical data in real time from the injection molding machines on the factory floor❒❒ Analyze process and production data and access real time reports❒❒ Improve molded part quality and labor productivity❒❒ Access plant-wide production information from anywhere in the world ❒❒ Automate the process of scientific molding to decrease mold set up time, cycle time and scrap

Let Moldflow Manufacturing Solutions take the weight off you. To find out more, contact us or go to our Web site atwww.moldflow.com to download our new Manufacturing Solutions white paper.

C O R P O R A T I O N

Moldflow Corporation430 Boston Post Road • Wayland, MA 01778 Tel +1 508 358 5848 • Fax +1 508 358 5868

www.moldflow.com

T H E R E A R E B E T T E R WAY S T O C O L L E C T D ATA F R O M YO U R I N J E C T I O N M O L D I N G M A C H I N E !

the polymer pages

"As far as the laws of mathematics refer to reality, they are notcertain, and as far as they are certain, they do not refer to reality."Albert Einstein (1879-1955)

On the surface, this may appear a strange way to begin adiscussion about a predictive capability that relies heavily onmathematics for its success. However the perspective it bringscaptures the essence of modeling such a complex physicalbehavior. In cases, such as the modeling of shrinkage, the generaltheory accurately captures the basic behavior and trends. However,the results are more useful if they can be made far more specific.

CRIMS (Corrected Residual In-Mold Stress) is a hybrid modelingtechnique that augments the mathematical theory used to predictshrinkage in injection molded parts. It works by comparing thisgeneral model to real molded samples and creating a function tominimize the difference. This function and its coefficients thenbecome part of the predictive model when used for realapplications.

The benefits of using CRIMS are too compelling to ignore.Moldflow analyzed nearly 20,000 moldings, each with variedprocess conditions, thickness, or material. The purpose was tocompare the accuracy of predictions based on mathematicaltheory alone and those based on CRIMS. Greater than 85 percentof the predictions based on CRIMS were within 20 percent of theexperimental result, whereas for the prediction based onmathematical theory alone, less than 15 percent of achieved thisresult.

Shrinkage background

As a brief introduction, Moldflow's approach to modelingshrinkage starts from the basic drivers for the phenomena. Amodel based on mathematical theory is used to simulate thosedrivers, which in turn is compared to the result of experimentalobservation and corrected to ensure that the model predicts whatreally occurs.

When shrinkage occurs in an unconstrained and undeformedmaterial, the material attempts to shrink equally in all directions(isotropically) as shown in Figure 1. The shrinkage itself is causedby the change in state of the material from a molten, high

pressure/high temperature state, as exists inside a mold, to a solid,low pressure/low temperature state, as exists at atmosphericconditions. For semi-crystalline materials, this change in stateincludes the crystallization process.

Inside the mold, the mold and its features resist this shrinkage,which in realistic moldings constrains all shrinkage to thedimensions of the mold with the exception of shrinkage across thethickness, where the material is free to move (Figure 2). Therefore,if the change of state requires that a certain volumetric changeoccur yet that change is resisted, a stress is built up in the material,which in turn begins to be relieved while the part cools in themold.

When the part is ejected from the mold, the constraint is removedand the remaining stresses cause a change of shape in the part thatwe know as shrinkage. Subsequent cooling will also cause thermalcontraction and more shrinkage.

There are other issues such as variations in crystallinity and thestresses due to the orientation of molecules and fibers that I willnot address here. For further information, please see the referencesat the end of this article.

The steps to solve this are:

1. Calculate the residual stress while the material is in the moldusing the calculated pressure-temperature history.

2. Using the residual stress, calculate the initial shrinkage at ejection.

3. Calculate additional shrinkage while the part cools to roomtemperature.

This is a general model called the residual stress model. The stepsare straightforward to describe. However, this is an example ofwhere the direct implementation of the mathematical model willresult in a model that predicts the trends but does not describereality with sufficient precision.

CRIMS

In order to calculate residual stress, a viscoelastic model withsuitable material data over the range of conditions encountered ininjection molding is required. In view of the temperature range ininjection molding, such a model must be valid in the melt state,during the phase change, and in the solid state. At this time nosuitable theoretical models are available. In order to make progressin simulation, some simplification is required. This simplificationintroduces errors that can make predictions from the simplifiedtheoretical model too inaccurate for use.

The solution to this problem is the CRIMS model. This is ahybrid model that utilizes measured shrinkage data to improve theprediction of shrinkage and warpage from theoretical models such

CRIMS, the Benchmark Standard forShrinkage Prediction

A. Roland Thomas, Moldflow Corporation


Figure 1 Figure 2

Volumetric Shrinkage Mold Restraint

Free

Free Free

Free

FreeFreeFixed Fixed


the polymer pages

as previously described. By comparing theoretical modelpredictions to experimentally measured shrinkages on moldedsamples, the CRIMS technique creates a function to minimize theerror. The coefficients of this function are the "CRIMScoefficients" and are stored in the Moldflow Material Database.When users perform perform shrinkage and warpage predictionson their parts, these coefficients are used to correct the calculatedresidual streseses and so minimize the error introduced by using asimplified model.

The CRIMS method may be used for filled and unfilled materialsand also performs well for polymer blends. It allows us toovercome the inaccuracy inherent in simplified models whileretaining the ability of these models to follow trends. It alsoenables predictions using conditions outside the range ofmeasurement of the samples used to obtain the coefficients.

The instrumented experimental mold is shown in Figure 3.Shrinkage values are measured both along and across the directionof flow under a variety of thicknesses and molding conditions.Figure 4 shows the measured results obtained for an unfilledpolypropylene. The anisotropy in shrinkage between the flow andcross-flow directions is evident. Figures 5 and 6 each showexperimental results, the mathematical theory result, and theCRIMS result for shrinkage in the flow and cross-flow directions,respectively. The improvement in the prediction is dramatic.

Moldflow supplies its mathematical model in both a CRIMS formand in a form that does not use measured values. The latter isuseful for showing trends, for example, how a change in processingconditions would affect shrinkage, and allows predictions usingthe over 7000 grades of thermoplastics in the Moldflow MaterialDatabase.

For more information we recommend the articles and books listedon the following page.

Figure 3. Diagram of MoldedShrinkage Sample

Figure 5. Measured and Calculated Shrinkages in the Flow Direction

Figure 6. Measured and Calculated Shrinkages in the Cross-Flow Direction

Figure 4. Measured Parallel and Perpendicular Shrinkage

For information on the Moldflow Material Database, CRIMSshrinkage modeling, or comprehensive material testing services,contact Moldflow Plastics Labs at [email protected].

References:

[1] Santhanam, N. and Wang, K.K., A Theoretical and Experimental Investigation of Warpage in Injection Molding, Soc. Plastics Engineers, ANTEC 90. 270-273, (1991).

[2] Kabanemi, K.K. and Crochet, M.J., Thermoviscoelastic Calculation of Residual Stresses and Residual Shapes of Injection Moulded Parts, Inter. J. Polym. Process., 7, 60-70, (1992).

[3] Lee, E.H., Rogers, T.G. and Woo, T.C., Residual Stresses in a GlassPlate Cooled Symmetrically from Both Surfaces, J. American Ceramic Soc., 48, No. 9, 480-487, (1965).

[4] Baaijens, F.P.T., Calculation of Residual Stress in Injection Moulded Products, Rheol. Acta, 30, 82-89, (1991).

[5] SWIS (Shrinkage Warpage Interface to Stress) Manual, Moldflow Pty. Ltd., Melbourne, 1990.

[6] Walsh, S.F., Shrinkage and Warpage Prediction for Injection Molded Components, J. Reinforced Plas. Compos., 12, 769-777, (1993).

[7] Rezayat, M. and Stafford, R.O., A Thermoviscoelastic Model for Residual Stress in Injection Moulded Thermoplastics, Polym. Eng. Sci., 31, 393-398, (1991).

[8] Zuidema, H., Flow Induced Crystallization of Polymers, Application to Injection Molding, Ph.D. Thesis, Eindhoven University of technology, 2000.

[9] G. Eder and H. Janeschitz-Kriegl and S. Liedauer, Crystallization Processes in Quiescent and Moving Polymer Melts Under Heat Transfer Conditions, Prog. Polym. Sci., 15, 629-714, (1990).

[10] Zheng, R. and Kennedy, P., Numerical Simulation of Crystallization in Injection Molding, Proc. 6th World Congress of Chemical Engineering, Melbourne, September 2001.

[11] Doufas, A.K., Dairanieh, I.S. and McHugh, A.J., A Continuum Model for Flow-Induced Crystallization of Polymer Melts, J. Rheology, 43, 85-109, (1999).

[12] T. Huang and M.R. Kamal, Morphological Modeling of Polymer Solidification, Polymer Eng. Sci. 40, No. 8, 1796-1808, (2000).

[13] R. Zheng, P. Kennedy, N. Phan-Thien and X.J. Fan, Thermoviscoelastic Simulation of Thermally and Pressure Induced Stresses in Injection Moulding for the Prediction of Shrinkage and Warpage for Fibre-reinforced Thermoplastics, J. Non-Newtonian Fluid Mech., 84, 159-190, (1999).


continued from Page 22


learning curves

Emphasis on CAE

Students who opt for the Technology Accreditation Commissionof the Accreditation Board for Engineering and Technology(TAC/ABET)-accredited plastics engineering technology (PLET)program at Penn State Erie, The Behrend College, get educationand training that make them "Impact Players" in the plasticsindustry, says John P. Beaumont, their professor, department chair,and a former technical manager at Moldflow. With the program'sunique integration of computer-aided engineering (CAE)programs into courses from the sophomore year forward, PennState Erie's PLET graduates are exceptionally well prepared tocompete in the plastics industry.

"I came to Penn State Erie with a mandate to develop the newesttechnology in the plastics industry and teach our PLET studentshow to use it," said Beaumont. "CAE is a continually evolvingtechnology, and since the program's inception we've made it partof our students' daily classroom experience."

"CAE is an accelerated learning tool, sort of like an X-ray thatgives you insight into how a plastics mold should be made toproduce successful plastic parts," said Beaumont. "A mold cancost a quarter-million dollars or more, so anything that ensures it'sproperly made saves time and money. We want Penn State Erie'sPLET graduates to be able to use CAE for just those reasons."

However, according to Beaumont, just as an X-ray needs a doctorto interpret results, CAE needs someone skilled to interpretanalysis results. Therefore, Beaumont and his colleagues require allstudents to complete industry-like projects using mold filling,cooling, shrinkage, and warpage analyses in both mold andproduct design courses.

PLET majors begin their computer foundation in the freshmanyear with solids modeling using Pro/ENGINEER®. In theirsophomore year they begin to use mold filling simulation in theplastics processing courses to better understand what occursduring molding. In the first semester of their junior year, studentsbegin a progression of design courses that deeply involve them inCAE technologies. During the junior year, they work withMoldflow's mold filling, cooling, shrinkage, and warpageprograms as part of mold and plastic part design classes. Inaddition to the details of modeling, studies at this level emphasizeinterpretation and practical application of CAE technologies.Further courses focus on structural analysis using ANSYS®software and thin-shell modeling and meshing usingPro/ENGINEER software for plastics applications. During theirsenior year, students continue to learn and apply CAEtechnologies in both required and elective courses. Throughoutthis process, the faculty requires students to link their knowledgeof plastic materials, processing, mold design, and part design;CAE technologies provide an efficient tool to connect all four ofthese areas.

Penn State Erie's PLETprogram has grown toinclude four engineeringcomputer labs with morethan 100 networkedcomputers running thelatest releases of CAEsoftware. Over the years,instructors have evaluateda variety of CAEprograms, but they havealways featured Moldflowsoftware, because of itsquality and US-basedsupport structure. As aresult, Moldflow employsa significant number ofPenn State Erie graduatesbecause of their solidunderstanding of the applications.

In addition to the fourPLET computer labs,the R.J. FasenmyerBuilding in theengineering complexhouses a plasticsprocessing laboratoryoutfitted by industrywith the most up-to-date equipment. Thelab, a 180-foot-long,two-story, high-baystructure with a five-ton overhead bridgecrane, is equipped withc o n v e n t i o n a lhydraulic, fullyelectric, and hybridprocessing machines.Adjacent to the

processing laboratory are three labs for water treatment, plasticsquality control, and rapid prototyping.

Student Opportunities

Since the beginning of the PLET program, Beaumont and otherfaculty have taken their students to the Society of PlasticsEngineers Annual Technical Conference (ANTEC) each Spring.In 1989, Penn State Erie presented three of the 11 student papersat ANTEC; in 1996, they presented 20 of 28 papers. In 2001,faculty escorted 59 students to ANTEC, where 27 papers werepresented and six won Best Paper Award in their student divisions.

Penn State Erie: Teaching the PlasticIndustry's "Impact Players" of Tomorrow


Overhead shot of plastics processing lab inthe R.J. Fasenmyer Building at PennState Erie.

Students utilizing Moldflow softwarein the engineering computer lab aspart of their course work at PennState Erie.

"The ANTEC opportunities provide unique experiences for thestudents," said Beaumont. "They learn to organize their thoughtsand go before a professional audience to defend their work. Oncethey do it, they've taken a major step toward proficiency andmaturity. The experience helps build confidence and publicspeaking skills."

One aspect of the PLET program that helps to make Penn StateErie's students "Impact Players" is the opportunity forinternational travel. Each year, faculty and upper-class PLETmajors attend an international plastics show outside the US. "Newtechnologies are showcased every year at international tradeshows," Beaumont said. "In addition to giving our studentsinternational competency — how to travel, eat, and live outsidethe American culture — we want them to see what's the latest andgreatest. We live in an international economy, and there is nodoubt we will continue to exchange technologies and productsaround the globe."

Applied Research Centers Make IndustryConnection

One beneficial result of Penn State Erie's PLET program has beenthe several outreach centers that resulted from the industryorientation of the program. The first, the Plastics TechnologyCenter (PTC), originated in 1989 when Beaumont and his

colleagues responded as consultants to the industry's request forhelp. The PTC also provided a mechanism to get studentsinvolved with real industry problems, and this remains a primaryobjective of faculty outreach activities. In a very short time, thedemand outgrew faculty time to respond, so they first hired a staffassistant, then hired their graduates as engineers. One of the firstto join the PTC was Jon Meckley, a former student who, afterworking for several years with the PTC and as a consultant,returned to the PLET program as a faculty member. Today anumber of former students currently work for the PTC.

Six years ago, Jon began to experiment with CAE applications inblow molding, the plastics technology used for molding hollowparts. Out of his work grew the Blow Molding Consortium,which serves the growing sector of the industry that uses thistechnology. The college, with the support of industry and grantsfrom the National Science Foundation, the PTC, and the BenFranklin Partnership, was able to acquire three blow-moldingmachines, several molds, and blow molding simulation software.Today, several regional plastics companies are members of theconsortium and receive support in the areas of training, productand process development, equipment selection, and processoptimization.

History

The concept of Penn State Erie's plastics program originated inthe early 1980s, when a group of local plastics manufacturingCEOs, including Hoop Roche from Erie Plastics, Joe Prischakfrom Plastek, and Bill Witkowski from Port Erie Plastics, askedthe School of Engineering and Engineering Technology at PennState Erie to consider developing a plastics engineering technologyprogram that would improve and advance the skill base of theiremployees. The college agreed, and by 1989 had a core group ofthree faculty, Robert Farrell, Paul Koch, and Beaumont, to get theprogram under way. Before coming to Erie, Farrell, a mechanicalengineer, was vice-president of engineering at Reed Machine, andKoch, a chemical engineer, was program manager for AveryInternational, Fasson Division. Beaumont was employed as thetechnical manager for Moldflow in Kalamazoo, Michigan.

Today, the PLET program enrolls more than 250 students. Newfaculty-educators who average more than 10 years of industryexperience-add practical knowledge to their teaching and industryoutreach. Together, the great faculty and the engineering staff ofthe PTC give the PLET program a total of more than 50 years'experience in the application of CAE technologies. By hiring newfaculty with expertise in materials and processing, and bynurturing its strong ties with the plastics industry, Penn State Eriehas built one of the strongest CAE educational centers in theworld.

learning curves


PLET majors traveled to China in 1997 to attend the Chinaplasshow in Shanghai.

For more information about Penn State Erie's PLET program,contact Loretta Brandon in the Office of University Affairs(tel: +1 814 898 6063, email: [email protected]) or visithttp://engr.bd.psu.edu/degrees/plet.html.

design & molding

Medical devicedevelopers arerapidly realizingthe benefits andchallenges ofusing CAD andmanufacturingtools, rapidp r o t o t y p i n gservices, mold

design and support services, and new Web-based product development resources.Speed-to-market was the mantra in the1990s and with the growth of — or ratherthe "shrinking of" — computerization,more features can be built into next-generation products.

High Tech but Easy-to-use I believe that in spite of all the hype aboutspeed and power and the ability to dothings better than ever before, we mustconsider other factors. The bottom line isthe ability to create a product that can andwill be used in a way that avoids setupproblems and mistakes in usage in the field,and offers intuitive simplicity. Medicaldevices provide life-saving therapies if usedproperly. They are used in several settings;emergency rooms, during critical surgery,and in the delivery of medication. Anymistakes in setup, use, or function of thedevice can put the life of the patient at risk.Fail-safe systems are not really fail-safe, ashas been repeatedly shown in reports ofuser-caused errors.

Medical device designers are faced withtough challenges, especially since regulatoryagencies worldwide are mandating fail-safeproducts. It is the responsibility of theproduct designer and engineer to create theproduct in a way that will meet the needs ofthe user as efficiently as possible while notcompromising the wealth of features thatcan be built into the product.

An Infusion PumpConsider, for example, a new infusionpump for IV drug delivery. The designengineer must understand issues such as:

❑ What solutions or drugs will the pump be used for?❑ Will it be used for high volume or slowinfusion of low volumes?❑ Are the drugs to be infused controlledsubstances that need to be stored securely?

❑ Who will use this pump - a trainedhealth care professional such as a nurse orphysician, or will it by used at home bythe patient or their family?❑ Where will the pump be used - in theemergency room, ambulance, intensivecare unit, on the hospital floor bedside orat home, or will it be for the activeambulatory patient?❑ Will this product be used in developingcountries?❑ What language or symbology will beused?❑ If the unit is in a harsh environmentwhat are the chances damage will beincurred? ❑ How will maintenance be performedand I.V. tubing and sets be changed?

A Clean Sheet of PaperThe designer starts with a clean sheet ofpaper and initiates designs that meet thephysical and functional requirements of theproduct. Considerations include the shape,colors, controls, and interfaces that give theproduct its unique characteristic that willappeal to the user and enhance their abilityto do their job. Ease-of-use and reliabilityseparate the mundane products from thegreat ones. The so-called plug-and-playproduct will more quickly be accepted bythe user than one that requires extensive in-service training to be able to use it.

The Layout, WallThickness, and MaterialsOnce the initial design layout is complete,the mechanisms, boards, cabling, andcontrols can be laid out more formally andbuilt into the design. CAD systems allowrapid assessment of space utilization andareas of interference. Proper materialselection can offer thinner wall sections,longer runs, and greater resistance tobreakage with better impact resistance. Byusing appealing, colored thermoplasticelastomers (TPEs) in the housing, aproduct can be given drop impactprotection and an enhanced appearance.Color displays that have high resolutionand readability from wide angles anddistance add to the tendency of the productto be used correctly. The science of humanfactor interaction with the user interfacemust be considered as new regulationsmandate systems that are designed toprevent mistakes.

The manufacture of the product with agood idea of annual volume requirementsmust also be considered early in the designof the product. This factor will dictate whattype of tooling will be built and used tomake the parts. If new software isdeveloped and used, it must be carefullyand extensively tested and validated.Meanwhile, during all this development,the regulatory requirements must be met.Design controls requirements need theattention of the design team throughoutthe development program, not just whenthe product is ready to be marketed. Aproperly run development program willsupport a filing to the FDA, for example,and the filing will be tremendously easier.

Inside or OutsourceProduct development programs of any sizecan be maintained and managed internallyor by outsourcing some components of theproject. Depending on the talent andresources on staff within an organization,the decision can be made to use the internalskill set or to rely on external experts. Formany companies, the use of outsideresources makes good business sense-allowing the company to do what it doeswell while outsourcing parts of the projectto outside pros. This collaborative effortresults in obtaining a better product, in lesstime, and for less cost.

It is the ultimate responsibility of thedesign engineer to develop the productsthat customers need, as well as adhere tothe requirements set for that product.Don't overlook the need for in-processproduct reviews. Evaluate and test theprototypes. Engage typical users with theproduct in the early stages of the program.The feedback from the non-informed,eventual user can be sometimes moreinsightful than a whole roomful ofengineers and designers. Consider theproduct from cradle to grave. Throughoutthe process, consider product lifecycle, aswell as disposability, waste disposal (arebatteries a disposable part of the product?)and whether the device is recyclable.

Finally, it can be a challenge to develop anew medical device given the currentengineering and regulatory environment.But, if executed properly, the process can beprofitable, gratifying, and an enjoyableoccupation!

Medical Device Design ChallengesBy Len Czuba, President, Czuba Enterprises, Inc.



what’s new

For certain types of part geometry, the gas-assisted injectionmolding process is a common alternative to conventionalinjection molding. However, the level of processing complexity isincreased versus conventional injection molding due to theinjection of the gas within the polymer melt. Understanding andpredicting the behavior and flow of the gas within the polymermelt is critical to achieving success in designing both parts andmolds for the gas-assist process. Through years of research andindustry alliances, Moldflow has developed an understanding ofnot only the gas-assisted injection molding process, but also howto accurately predict the flow behavior of both the polymer meltand the injected gas. Furthermore, in Moldflow Plastics Insight™

3.0 (MPI™ 3.0), the capabilities of MPI/Gas have beensignificantly extended (MPI/Gas is the MPI module forsimulating the gas-assist process). MPI/Gas now interfaces withboth MPI/Warp and MPI/Fiber to predict both the shrinkage andwarpage of gas-assisted injection molded parts, as well as topredict the effects of fibers during the filling of the part and theeffect of the fibers on post-molding shrinkage and part warpage.MPI/Gas recently introduced capabilities that benefit those whoneed to optimize part and mold designs, as well as the gas-assistedinjection molding process itself.

The gas-assisted injection molding process has found a nicheamong certain types of applications such as television cabinets,automotive interior door handles, appliance parts, toys, and manyothers. It is common knowledge that by using the gas-assistprocess, it is possible to produce parts that are rigid, devoid of sinkmarks, and have a lower tendency to warp. The gas-assist processalso has been proven to reduce material consumption, machineclamp tonnage and cycle time. The gas-assist process is frequentlyused to produce complex parts that consist of a combination ofthick and thin sections.

Because the gas-assist process involves the dynamic interaction oftwo rheologically dissimilar materials flowing within typicallycomplex mold cavities, the optimization of the part design, molddesign, and process conditions is, at best, extremely difficult.Furthermore, even years of experience with conventional injectionmolding are not sufficient to deal with the gas-assist process,especially in designing the gas-channel network and optimizingthe processing window.

MPI/Gas is a powerful software tool that provides the know-howto better understand the complexities of the gas-assisted injectionmolding process. The knowledge gained from using MPI/Gastypically equates to improved part and mold design and thereduction or elimination of problems during the production ofgas-assist parts. The software assists part and mold designers in:

❑ Evaluating material selection for gas-assisted injection molding part design.

❑ Optimizing the plastic part design to obtain the desired gas penetration.

❑ Evaluating mold design options and their impact on gas penetration.

❑ Determining the appropriate processing conditions for producing acceptable quality parts, including the volume of plastic to inject and the timing of the gas injection.

New MPI/Gas Analysis Capabilities

New with the release of MPI 3.0, the MPI/Gas analysis modulesupports the simulation of shrinkage and warpage of a gas-assistpart through an interface to MPI/Warp. As a result, it is possibleto estimate the residual stresses in the gas-assist part and considerthe effects on part warpage. All things being equal, a gas-assistmolded part typically will be more structurally rigid versus thesame part made by the conventional injection molding process.Part designers can now validate this in the early stages of partdesign, where the cost of change is minimal and the impact of thatchange is greatest.

Below is an example of an actual part produced by conventionalinjection molding, which was found to have an unacceptableamount of post-molding warpage. The same part was moldedusing the gas-assist process in an attempt to reduce warpage towithin acceptable tolerances. The design was slightly modified toadd flow leaders, which served as the gas channels and which werethe primary source of gas coring.

The images that follow indicate the out-of-plane displacementusing conventional injection molding and gas-assisted injectionmolding. It can be seen that the image on the left, produced byconventional injection molding, has significant warpage, while theimage on the right, the gas-assist part, is relatively flat. The

Moldflow Extends the Capabilities ofMPI/Gas in Moldflow Plastics Insight 3.0

By Dean Piepiora, Moldflow Corporation

what’s new


bottom image displays the predicted penetration of the gaschannels, seen as an X across the surface of the part.

In MPI 3.0, MPI/Gas users can also benefit from a new interfaceto MPI/Fiber, which allows for the accurate simulation of the gas-assist molding process with fiber-filled plastics. Fibers such as glassand carbon are often added to plastics to improve the structuralperformance of the final molded parts. These parts are often largerin nature and lend themselves to the gas-assisted injectionmolding process to reduce wall thickness, part weight, warpage,and cycle time. The complexities of injecting fiber-filled plasticswith gas can now be simulated in MPI 3.0 to help ensure that themolded parts will be of acceptable quality.

In addition, MPI/Gas flow results can be used as an input to anMPI/Cool analysis, allowing users to study the impact of acooling-line layout on gas penetration and cycle time. Thecooling-line layout can be modified to improve the overall coolingof the part, as well as to promote gas penetration.

Conclusion

Because of the inherent complexities of the gas-assisted injectionmolding process, it is necessary for companies to understand thebehavior and flow of the gas within the polymer melt in order tooptimize part design, mold design, and the gas-assisted injectionmolding process itself. The MPI/Gas module of the MoldflowPlastics Insight product line provides the tools required toaccurately predict the behavior of both the gas and polymer withinthe gas-assist process so that users can optimize their part andmold designs with confidence. Furthermore, in MPI 3.0, thecapabilities of MF/Gas have been significantly extended. MPI/Gasnow interfaces with MPI/Warp to predict both the shrinkage andwarpage of gas-assisted injection molded parts, and withMPI/Fiber to predict the effects of fibers on the filling of the partand the effect of the fiber orientation on post-molding shrinkageand part warpage.

For more information about Moldflow Plastics Insightproducts, visit www.moldflow.com or contact your localMoldflow representative


the analyst says

Marc Halpern is an analyst for theGartner Group in New York.

In the current era of consumer-drivenmarkets, companies must improvetheir ability to innovate. Yet, ananalysis of R&D spending data from48 Fortune 500 companies shown onthe figure below, suggests that theresearch and development capacityof corporations is declining.1

Therefore, manufacturersare challenged withimproving the efficiency ofR&D without negativelyimpacting their ability toinnovate.

The bars on the figuresuggest that the cost of R&Dhas been rapidly acceleratingfrom 1998 through 2000. Yet,research and developmentinvestment remains constantat an average of six percentof total revenues for these 48manufacturers. Since thesecorporations will probablymaintain the six percent levelof R&D spending while thecost of R&D will continue to increase,the net R&D capacity of manufacturerswill decline with increased pressure onrevenues in these difficult economictimes.

Businesses can increase their R&Dcapacity through adoption of broad-based business imperatives thateliminate waste and simultaneouslytake steps to improve R&Dperformance. Elimination of waste canadd financial and human resources thatcan be applied to high priority R&Dinitiatives. R&D capacity improveswhen businesses apply the increasedresources to an R&D organization thatcan perform better. Broad-basedbusiness imperatives that cut wasteinclude customer retention,elimination of unnecessary IT expense,and Product Portfolio Management.

Gartner estimates that it can cost up to40 times more to attract a newcustomer than to keep a current one.So retaining just five percent morecustomers can translate into savings of25 percent to 55 percent inprofitability. Also, companies thatprioritize customer-service processes,people, and technology will be betterpositioned for the economic reboundwith more loyal customers.

When appropriate, companies shouldseek opportunities to make IToperations more efficient.Opportunities include reducing thediversity of desktop operating systemsand office applications, reducing thenumber of levels of IT services to theminimum needed, eliminatingunnecessary physical moves bypersonnel, seeking ways to reducesupport costs for geographicallydisperse users, and eliminatingunnecessary rollouts of softwareupdates. Gartner research indicatesthat large enterprises with 10,000 usersor more can save in excess of $300 peruser per year, or $3 million.

Product Portfolio Management (PPM)can improve time to completion ofR&D efforts by 40 percent according toearly adopters by establishing objectiveand systematic methods to prioritize

new product and program initiatives.PPM incorporates financial tracking,human resources management,technical risk assessment, and marketopportunity to reach consensus on howto work smarter and which tools toinvest in to attain that goal. Mostcompanies do not have this discipline.Consequently, they rarely understandhow R&D dollars and time are beingspent. Successful companies focus their

efforts on the programs thatmatter withoutcompromising on the qualityof R&D conducted.

Further, Product PortfolioManagement should besupported with project andprogram managementapplications that assist inthe management ofdevelopment effortsinvolving multiple nestedprojects. Adopters ofproject management toolswith design collaborationfunctionality report 20percent to 30 percent

improvement in the time and cost tocomplete individual projects.Program management softwarehelps realize the time and costsavings by enabling managers todetect and resolve resourcebottlenecks.

Companies must invest to achieveProduct Portfolio Managementbenefits. Adopters report costs rangingfrom $250,000 to $1 million over twoto 12 months to deploy a ProductPortfolio Management environment,depending on the scope of theimplementation. Adopters must alsohave the support of seniormanagement to establish and enforcethe new business processes and todedicate a team to execute thedeployment.

1 Raw data published by Technology Review.

Managing Innovative ProductDevelopment in Tough Economic Times

By Marc Halpern, Research Director, Gartner Group

Harry “Hercules” Adams: Ski equipmentBob “The Conqueror” Carson: Assembly machinery Steve “Invincible” Thomas: Medical instruments

New SolidWorks Office. More than a great value, it gives you

quite a powerful feeling.You can do it all. Now everything you need to beef-up your productivity and add more

muscle to your presentations is in your hands. You are the product designer with all the tools: ■ SolidWorks® 3D CAD software ■ PhotoWorks™ ■ SolidWorks Animator ■ 3D Instant Website

■ SolidWorks Toolbox ■ FeatureWorks® ■ SolidWorks Utilities. You have all the power in one very affordable package. SolidWorks Office, the complete 3D CAD solution. Find out more, big guy.

Log on to: www.solidworks.com/flowpower or call 1-800-693-9000 ext. 3556.

©2001 SolidWorks Corporation. SolidWorks and the SolidWorks logo are registered trademarks and PhotoWorks is a trademark of SolidWorks Corporation. FeatureWorks is a registered trademark of Geometric Software Solutions Co. Limited. All other company and product names are trademarks of their respective owners.

Documents

The Magazine of Choice for Plastics Professionals › uploads › 1 › 3 › 5 › 8 › 13585698 › ...The Magazine of Choice for Plastics Professionals industry education Viscount