CONNTECT! Moldflow® User Meeting 2011 - Tuesday, 17. 05. - Wednesday, 18. 05. 2011 Frankfurt



Autodesk Financing

Stream Engeneering

HRS Flow

Volume Graphics GmbH







John Beaumont, Beaumont Technologies, Inc. (US)

Dario Loaldi, Technical University of Denmark (DK)

Frank Schäufele, Walter Söhner GmbH & Co. KG (D)

Prof. Gerrit W. M. Peters, Technische Universität Eindhoven (NL)

Petrus Jakimenkow, IMI Precision Engineering Buschjost GmbH (D)

Rasmus Knudsen, Novo Nordisk A/S (DK)

Susanne Kugler, Robert Bosch GmbH (D)

Harindranath Sharma + Prasanta Mukhopadhyay, SABIC Research & Technology Centre (IN)

Dr. Andreas Wonisch, BASF SE (D) + Matthew Jaworski, Autodesk Inc. (US)

Paul Borger + Bartlomiej Piotrowski, BSH Hausgeräte GmbH (D)

Dr. Robert Wesenjak, e-Xstream engineering, an MSC Company (LU) + Dr. Sebastian Mönnich, PEG GmbH (D)

Matthew Jaworski, Autodesk Inc. (US)

Patrick Koblenz, Dr.Schneider Holding GmbH (D)

Patrizia Scholz, Clariant Plastics & Coatings GmbH (D) + Michael Gossen, PEG GmbH (D)

Aniket Raje, Röchling Automotive SE & Co. KG (D)

Coen Hartjes, Thermoplastic Composites Research Center (NL)


Commitment to Success

The injection molding of plastic parts is an extremely complex and is often oversimplified. Despite significant advancements over the years, our industry is still struggling to understand and manage the extreme conditions experienced by a melt as it flows through a mold and forms into a plastic part. After over 40 years since the introduction of injection molding simulation, these extreme conditions continue to handicap the development and application of this technology. If we are to be committed to success, we must continually challenge and question what we think we know. We must recognize that today’s state-of-the-art is simply tomorrows outdated practices and therefore must continually strive to do better. This talk will present some of the research and development at Beaumont Technologies, including Thermaflo, MFCheck and MeltFlipper, designed to capture and manage some of the issues our industry is challenged with.



John Beaumont, Beaumont Technologies, Inc. (US)

John Beaumont is the founder and President of the Beaumont group which includes Beaumont Advanced Processing and the American Injection Molding Institute. He has authored several books on Injection Molding and is a 2014 inductee to the Plastics Hall of Fame. John is also a Professor Emeritus at Penn State University where he helped develop and chaired the Plastics Engineering Technology Program at Penn State University. He has several patents that deal with in-mold rheological control and polymer melt characterization. His earlier industrial credits include positions as Technical Manager for Moldflow’s US operations and Engineering Manager for Ciba Vision Corp. He was the founder and director of the Plastics CAE Center at Penn State, is a member of the Plastics Pioneers and an SPE Fellow.


Multi-scale 3D-Modelling of the Filling Behavior of Micro Structured Plastic Optical Components

During the injection molding of micro structured optical components, such as for example Fresnel lenses, the filling parameters of the process have to be tuned in a way that both the microstructures and the full part scale meet the geometrical specifications to achieve the desired functionality. Process aspects such as formation of weld lines, cavity balance, hesitation and full replication of the micro features can be predicted using simulation. To do so, governing equations, boundary conditions and model geometry have to be developed and validated for the multi-scale nature typical of micro structured components. In this research, 3D modelling of the filling behavior of a micro structured Fresnel lens was performed using the Moldflow® software. Meshing using selected domain regions together with localized selection of HTC (Heat Transfer Coefficient) was critical for the experimental validation of the models both at the micro and the macro dimensional scale, which was performed using an integrated approach including the injection molding short shots method, optical coordinate metrology and laser confocal microscopy.



Dario Loaldi, Technical University of Denmark (DK)

Dario Loaldi studied Mechanical engineering at Politecnico di Milano (IT). After completing a general Mechanical Engineering Bachelor degree, during his master he specialised in “Advance materials and manufacturing processes”. During this two years program he spent one semester at the RWTH University (DE) as part of Erasmus+ program and he concluded his master at the Technical University of Denmark, DTU (DK), where he write a thesis on the metrological characterisation of injection compression moulded micro polymer Fresnel surface. He is currently working on a PhD research project at DTU (DK) in the field of micro and nano structures replication. He focuses on the implementation and validation of process chains for the integration of micro/nano strucutres on consumer polymer products. He his using Moldflow to create a process digital twin for micro nano replication.


Validation of the Moldflow Prediction of Sink Marks and Voids Using Series Products And Test Components

In technical plastic components, voids and sink marks are frequently occurring failure characteristics which range from optical failure to component failure. In order to avoid voids and sink marks in the development phase and to show customers possible effects, exact prediction methods are necessary.

Moldflow Insight offers various possibilities for this, e.g. the analysis of volume shrinkage. Since volume shrinkage values do not allow a direct statement on the depth of the sink marks and/or the size and number of the voids extensive tests for validation have been carried out.

The main focus was on glass fibre reinforced PA and PBT. The results and their interpretation will be presented in extracts during the lecture.




Frank Schäufele, Walter Söhner GmbH & Co. KG (D)

Frank Schäufele is team leader for product optimization / simulation at the innovation center of Walter Söhner GmbH & Co. KG in Schwaigern. After his education as a tool technician he studied mechanical engineering at the University of Karlsruhe. Starting with his bachelor thesis in 2012, he worked in various departments of Walter Söhner.


Flow Induced Crystallization of IPP: Modelling Multiple Crystal Phases and Morphologies

Depending on the conditions, Isotactic Polypropylene (iPP) can form different crystalline phases and different crystalline morphologies, as it can be clearly seen in injection moulding samples by applying X-ray scattering methods. Over the sample thickness, a distribution of four different phases (a, ß, ?, meso) and multiple crystalline morphologies (spherulites and shish-kebabs) is found that depends on the local thermo-mechanical history. A prototype industrial flow device (piston driven slit flow) combined with in situ wide angle X-ray diffraction and small angle X-ray scattering was used to measure the evolution of the (oriented) crystalline structures and phases (a, ß, ?) for different flow conditions. On the basis of the experimental results, an accurate model was developed, able to describe flow induced crystallization of isotactic polypropylene at high pressures and shear rates. In the present work, the model is implemented in a two-dimensional finite element solver and fully coupled with nonlinear viscoelasticity, compressibility and non-isothermal flow equations. The build up and relaxation of the pressure difference and the development of the different structures and phases during and after flow are accounted for. Simulations are run for a wide range of imposed pressures and piston speeds and the model is tuned to represent the interaction between the crystallization process, the thermo-mechanical conditions and the rheological properties of the polymer. Quantitative agreement with experiments is obtained.



Prof. Gerrit W. M. Peters, Technische Universität Eindhoven (NL)

Gerrit Peters is a Full Professor at Eindhoven University of Technology (TU/e) in the Netherlands, where he is Chair of Theoretical and Applied Rheology. Key areas of expertise are rheology of polymers and soft tissues and structure development during polymer processing. His current research focused on these areas, more specifically on constitutive modeling of mechanical induced phase changes and structure–property relations. Applications are found in film blowing, extrusion, injection molding and electrospinning of amorphous, semi-crystalline and reactive polymers. His work also incorporates the development of dedicated experimental setups such as, for example, a unique dilatometer (the Pyrouette) that allows for high cooling rates and sample shearing.


Analysis of Causes and Process Optimization of Plastic Parts With Thermo-mechanical Failure Characteristics via Moldflow Simulation

The development and design of complex technical plastic components is a special challenge and in practice often leads to a compromise between economic, technical and manufacturing requirements for the component.

While the use of Moldflow simulations for molded part and mold optimization is now state of the art, the subsequent DoE simulation remains unused in many cases. This tool can be used successfully for the optimization of moulded parts and processes in order to prevent quality problems in advance.

How Moldflow can be used as a tool to analyze the causes of molded part defects and the subsequent optimization of the injection molding process is illustrated in this paper using a practical example on a valve housing made of PPSU with thermo-mechanical failure pattern.




Petrus Jakimenkow, IMI Precision Engineering Buschjost GmbH (D)

Before studying mechanical engineering in the field of plastics technology, Petrus Jakimenkow first qualified as a cutting machine operator at Jäger Maschinenbau GmbH in Porta Westfalica.

Already during his studies at the FH Bielefeld he worked for the company IMI Precision Engineering Buschjost GmbH, where he was employed as a development engineer in the field of development and design of technical plastic components after his graduation in 2016.

Since 2018 he has the position as a qualified tool designer for injection molding tools.



Standardisation, Automation and Democratization of Early Phase Moldflow Simulation Through Application Programming Interface

In Novo Nordisk developing a new injection device for drug delivery, e.g. insulin, takes a long time. Often 10.000 or more iterations are needed, each of them adding maturity, but on other side requiring time! It is estimated that the 80% of the engineering hours are spent in building, testing and verification of models – either as physical models (3D printing and soft tool moulding) or virtual models (e.g. structural and moulding simulations).

The Engineering Analysis Department delivers approximately 500 simulations pr. month. This covers structural, moulding and tolerance simulations/calculations. We have a dream: Being able, within a few years, to run a complete virtual test program of a device overnight with a single mouse click.

To fulfil our dream and at the same time speed up development time, we need to change the way we perform and think simulations by:

- Making it fast and simple to do virtual testing

- Doing more virtual testing, by increasing capabilities within virtual testing.

This presentation will focus on how the use the Application Programming Interface in Moldflow has reduced our average lead time on early phase simulations from 2 days down to 2 hours. It will show how design engineers with less than 5 mouse clicks are able to start an automatic Insight Moldflow simulation, and have the mouldability of their part evaluated and the results presented in a simple and easy-to-understand dashboard format.




Rasmus Knudsen, Novo Nordisk A/S (DK)

Rasmus Knudsen is a senior research scientist in the Engineering Analysis department in Novo Nordisk. He studied Mechanical Engineering at the Technical University of Denmark where he obtained his B.Sc. in 2010 with focus on plastics and simulations. Prior to this, he concluded a 3.5 year practical education in 2005 as an injection moulding process technician.

Since hired in Novo Nordisk 2010, he and his 12 colleagues in the Engineering Analysis department have been supporting the approximately 200 engineers working in the organization Device Research & Development with structural simulations, optimized moldability, tolerance and kinematic calculations. In 2017 he established a DRD moulding lab, to further support projects with moulded prototypes, test-specimens for material characterization and feasibility testing of new injection moulding technologies.



Simplified Coupling of Flow and User-defined Fiber Orientation Using Moldflow's Solver API Feature

Short fiber-reinforced thermoplastics are a promising substitute for metal parts, since they are easy to process and show high mechanical strength. Accurate simulative prediction of failure and lifetime of such polymer parts can reduce development costs significantly. This can be achieved by implementing more precise material models to describe the various properties. Additionally, the rheological properties of fiber-reinforced parts are anisotropic and dependent on the fiber orientation. Therefore, a coupling between flow and orientation increases the prediction accuracy. In this presentation, we focus on the implementation of a state-of-the-art fiber orientation model and a simplified coupling to the flow using Moldflow’s Solver API feature. The main motivation behind this work is to obtain a better prediction of the fiber orientation in a simple plate in comparison to measured results.



Susanne Kugler, Robert Bosch GmbH (D)

Susanne Kugler holds a Master's degree in Mathematics from the Karlsruhe Institute of Technology. During her studies she spent one year at the Royal Institute of Technology in Stockholm, Sweden (with ERASMUS?).

Since 2017 she is a PhD student at the Institute of Polymer Technology at the Friedrich-Alexander-University, Erlangen-Nuremberg, where she is doing research on "Improved prediction of fiber orientation in thermoplastic polymer melts" for the Research and Advance Engineering division of Robert Bosch GmbH.



The Significance of Rheometry Technique for Accurate Estimation of Polymer Melt Viscosity – its Measurement, CAE Simulation and Molding Process Validation

For an accurate CAE simulation of a high-pressure injection molding process, it is important to understand the pressure sensitivity of a polymer’s melt viscosity, setting up a systematic experimental molding (validation tool) process and accurately modelling the same in CAE tool, to validate the results. This work describes rheometry methods for accurate estimation of polymer melt viscosity, including combination of capillary and dynamic rheometer and choice of appropriate dies. In addition, we present a validation methodology that provides insights into systematic approach and detailed steps typically required to represent the FE model better. This improves the overall accuracy and confidence on some of the key results obtained from CAE tools. This methodology covers critical aspects like measurement and influence of true melt temperature and reduce their uncertainty while using them as inputs in CAE. All these studies provided insights about the process and formed the basis for setting up the model. This model is more representative of the actual process consisting of the part, material, flow channels and initial temperature conditions. Using this approach and with the inclusion of an improved resin viscosity characterization data in the CAE model, SABIC demonstrated predictions of the peak pressure of select resins within an acceptable range, of its actual value as measured in the mold.



Harindranath Sharma, SABIC Research & Technology Centre (IN)

Harindranath Sharma obtained Masters’ Degree in 2000, in Mechanical Engineering with Specialization in Tool Engineering from NTTF-School of Post Graduate Studies, Anna University, India. He started his career as a tool designer developing molds and press tools for precision components. Later moved on and gained expertise in Design, CAE simulations, Polymer testing and Injection molding process. Currently member of Global Application Technology team in SABIC, pursuing developemnt of new applications in automotive and industrial segments.




Prasanta Mukhopadhyay, SABIC Research & Technology Centre (IN)

Prasanta Mukhopadhyay obtained Masters’ Degree in 1995, in Polymer Science and Technology from University College of Science and Technology, Calcutta, India. He started his career in Manufacturing in Compounding and Molding operations. Later moved on and gained expertise in Product management and various Technology development roles. Currently member of Global Analytical Technology team in SABIC, pursuing development of new methods and solutions for industry providing polymer functionality insights from structure-property understanding.


The Hottest Design, Manufacturing and Simulation Methods for the Coolest Molds

Kühlkanäle für Kunststoff-Spritzgießwerkzeuge sind so konzipiert, dass sie die Wärme aus der Kunststoffschmelze in der Kavität effizient und gleichmäßig ableiten. Traditionell gebohrte Kühlkanäle sind jedoch durch ihre charakteristische geometrische Geradlinigkeit in Bezug darauf begrenzt, wie nah sie komplizierten und komplexen Kavitätenformen folgen können. BASF und Autodesk haben den technologischen und wirtschaftlichen Nutzen alternativer Herstellungsverfahren untersucht, welche eine effektivere und konturnahe Kühlung ermöglichen. Wir beschreiben das Design, die Simulation, die Herstellung und die Überprüfung von drei konkurrierenden Verfahren: traditionelle gebohrte Steiger, Metalldruck und Vakuumsysteme. Mit der Autodesk Moldflow-Software simulierten wir zuvor die Wärmeleistungen der einzelnen Designs. Die Ergebnisse wurden dann mit Spritzgießversuchen im BASF-Verarbeitungslabor verglichen. Anschließend wurde die Zykluszeit für alle drei verschiedenen Kerne gemessen. Erfahren Sie, wie gut wir die Zykluszeiten für die Kerne vorhergesagt haben und wer der ultimative Gewinner in Bezug auf Leistung und Kosten war und warum das so war.



Dr. Andreas Wonisch, BASF SE (D)

Dr. Wonisch studied physics at the University of Bielefeld. After completing his diploma at the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg, he received his doctorate in the field of simulation of granular media and complex fluids and was awarded the Materials Mechanics Prize of the Plansee Mitsubishi Group for this work in 2009. Until 2011 he was a research assistant at the Fraunhofer IWM and has been working for BASF SE since then, focusing on the rheological behaviour of technical plastics, numerical optimization and model development. In 2015 he assumed the position of Team Leader Process Analysis.




Matthew Jaworski, Autodesk Inc. (US)

Matt Jaworski is a Senior Subject Matter Expert for Autodesk’s Moldflow Simulation Team. He has over 21 years’ experience in the injection molding CAE simulation field working for such companies as Erie Plastics, Hewlett Packard, Rubbermaid and Moldflow/Autodesk. He has dual BS degrees in Mechanical and Plastics Engineering Technology from Penn State, a MS in Plastics Engineering from UMass Lowell and is currently finishing his Ph. D. at UMass Lowell in Plastics Engineering on the research subject of weld line strength prediction. He is a member of the Society of Plastics Engineers and the American Society for Engineering Education. Matt is also active in education and has taught at the University of Massachusetts Lowell and Penn State Erie, The Behrend College as an adjunct professor.


Moldflow Project Buddy - Synergy API Tool to Organize Moldflow Projects

Simulation plays an important role in increasing efficiency in the development of plastic components for modern domestic devices. As a result, both the number and size of Moldflow projects and models are increasing. For this reason, handling in post-processing is becoming more and more important. The Moldflow Project Buddy application, specially developed according to the requirements of BSH Hausgeräte GmbH, helps to improve the overall view of Moldflow projects. The studynotes contain an automatic summary of the simulation settings. Projects can be handed over to colleagues without any complications or loss of information. The additionally generated spreadsheet overview of selected parameters also allows project metadata to be archived. The presentation will include an application demonstration to illustrate the advantages in day-to-day use.



Paul Borger, BSH Hausgeräte GmbH (D)

Paul Borger is M. Eng. Plastics Engineering. Until graduating at the Darmstadt University of Applied Sciences, he dealt with a wide range of topics relating to plastics. He already worked with Moldflow during his studies at PEG GmbH. His Bachelor's degree focused on the subject of "Functionalization of Plastics" (Robert Bosch GmbH) and his Master's thesis at BASF SE was on "Influence of material data of fiber-reinforced thermoplastics on the integrative simulation of building components". Since 2017, he has worked as a development engineer at BSH Hausgeräte GmbH in the area of laundry care.




Bartlomiej Piotrowski, BSH Hausgeräte GmbH (D)

Bartlomiej Piotrowski also completed his master's degree. He received this degree in general mechanical engineering from the Frankfurt University of Applied Sciences. During his student career he also worked with Moldflow at PEG GmbH, wrote his bachelor thesis at Daimler AG on "Injection point optimization with regard to component distortion and injection pressure and his master thesis dealt with "FE optimization of a diving mask. Like Paul Borger, he has been a development engineer at BSH Hausgeräte GmbH since 2017.


Digimat in Use for Integrative Simulations – Various Composite Materials and Applications

The design and layout of fibre-reinforced plastics is a challenge for engineers. In contrast to conventional materials, such as metals, the anisotropy of the physical properties of fiber-reinforced materials cannot be neglected. Various factors such as fiber orientation, weld lines, temperatures, strain rates, etc. have a significant influence on the stiffness and strength of the material, as well as on the type and limit of failure. Digimat provides a multi-scale material modelling strategy to take into account the above-mentioned dependencies of stiffness and strength and allows for an accurate prediction of failure. Digimat forms the bridge between manufacturing simulation - e.g. fiber orientation and weld line information from Moldflow - and structural simulation. The coupling is based on special micromechanical material models, which use the local fiber orientation to determine the material properties. However, Digimat is not only a tool for material specialists. The platform also offers tools such as Digimat-RP, which can be used to perform integrative simulations without in-depth knowledge of materials science.



Dr. Robert Wesenjak, e-Xstream engineering, an MSC Company (LU)

Robert Wesenjak studied mechanical engineering at the TU München. Subsequently, he worked as a research assistant at the Institute of Materials Science and Mechanics of Materials at TUM on the mechanical behaviour and damage of dual-phase steels. After completing his doctorate, he worked at TWT-GmbH on issues in the field of chassis dynamics. Since August 2017 he has been working at e-Xstream engineering as an application engineer in the area of customer service and technical support for the software Digimat.




Dr. Sebastian Mönnich, PEG GmbH (D)

Sebastian Mönnich studied mechanical engineering at the TU Darmstadt until 2009.

From 2009 to 2012 he was a research associate at the German Plastics Institute and took over as head of the "Mechanics and Simulation" group at the Fraunhofer LBF in 2012.

December 2015 he received his doctorate at the Otto-von-Guericke University Magdeburg.

Since 2017 he is working for PEG Gmbh as the leader of the team for structural process simulations.


Weld Surface Strength Analysis and Mapping As-manufactured Properties to Structural Simulation

Weld surfaces (commonly referred to as weld lines or knit lines) occur during an injection molding process in which multiple gates are used or after an obstacle or thickness variation. When the flow fronts recombine, a weld surface is formed that can cause a significant reduction in the mechanical strength of the part. Moldflow is commonly used to predict the formation location and movement of weld surfaces, but in order to understand the implications the weld surface has on a part's structural performance, the weld surface information needs to be transferred to the structural FEA model. In this presentation, details of the workflow process, including material testing and properties requirements will be shared along with validation examples.



Matthew Jaworski, Autodesk Inc. (US)

Matt Jaworski is a Senior Subject Matter Expert for Autodesk’s Moldflow Simulation Team. He has over 21 years’ experience in the injection molding CAE simulation field working for such companies as Erie Plastics, Hewlett Packard, Rubbermaid and Moldflow/Autodesk. He has dual BS degrees in Mechanical and Plastics Engineering Technology from Penn State, a MS in Plastics Engineering from UMass Lowell and is currently finishing his Ph. D. at UMass Lowell in Plastics Engineering on the research subject of weld line strength prediction. He is a member of the Society of Plastics Engineers and the American Society for Engineering Education. Matt is also active in education and has taught at the University of Massachusetts Lowell and Penn State Erie, The Behrend College as an adjunct professor.


Validation of DoE in Moldflow with Focus on Minimizing Warpage

The first trial of injection molds is a major challenge, especially for more complex components. How quickly an operating point for the process is identified often depends on the individual experience of the specialist and is difficult to be taught.

To solve this problem Moldflow offers the possibility of a DoE. Here simulations with different process settings are set up in test plans. The results are evaluated by the software in order to generate statistically optimized parameters for basic settings of the injection molding machine, such as melt temperature, mold temperature, injection time or holding pressure.

Parameter settings optimized for warpage were calculated using the DoE and set on an injection molding machine. In order to validate the results, the molded parts of all test series were measured with an optical measuring system and compared with the CAD model in order to determine the warpage changes compared to the original process.



Patrick Koblenz, Dr.Schneider Holding GmbH (D)

Patrick Koblenz is a student at the Würzburg-Schweinfurt University of Applied Sciences in the master's programme "Product and System Development". During his bachelor studies in "Plastics and Elastomer Technology" he worked at the Fraunhofer Institute ISC for Silicate Research and at the South German Plastics Centre SKZ. He wrote his bachelor thesis at Dr. Schneider Kunststoffwerke GmbH, where he carried out investigations on the Design of Experiment-Tool in Moldflow. Since completing his bachelor's thesis at the end of 2018, he has been working as a student trainee for Dr. Schneider in the field of simulation


Hydrocerol® in Automotive Applications and How to Simulate with Moldflow

High demands are placed on plastic components in automotive applications. In addition to good surface quality and high dimensional accuracy, weight savings are becoming increasingly important. In addition, the components must be produced cost-efficiently and in large quantities.

Chemical blowing agents from Clariant under the trade name Hydrocerol® can help.

In this lecture, the advantages of foamed components and some sample applications will be presented. In addition, the possibilities Moldflow offers for simulating the injection molding process with chemical blowing agents will be demonstrated.



Patrizia Scholz, Clariant Plastics & Coatings GmbH (D)

Patrizia Scholz studied chemistry at the University of Applied Sciences in Gelsenkirchen, which she successfully completed in 2007 as a graduate chemist.

In her diploma thesis at the Max Planck Institute she investigated the enantioselective rhodium-catalyzed olefin hydrogenation.

Immediately after graduation, she worked in the analytical department of Clariant Masterbatches, where she was primarily responsible for the development of new analytical and quality control methods and for error analysis.

In 2009 she joined the product development team of Clariant Masterbatches. She was responsible for the development of new additive masterbatches with a focus on nucleating and chemical blowing agents.

Since 2018, Ms Scholz has been Product Manager for the automotive sector in Europe.


Michael Gossen, PEG GmbH (D)

Michael Gossen studied Plastics Engineering at University of Applied Sciences in Darmstadt.

In his Bachelor thesis at sauer product GmbH, he investigated the warpage behavior of physically foamed components and completed his studies as the best in his class.

During the subsequent master's degree Mr. Gossen developed his interest in process simulation with Moldflow and started working for PEG GmbH.

After his master thesis in the field of draping simulation, which he completed at BASF SE, Mr. Gossen returned to PEG GmbH at the end of 2015 and has been working there since April 2016 as project manager/simulation engineer.


Gas Assisted Injection Molding: Successful Mechanical Simulation through Successful Process Simulation

A high strength to weight ratio is highly desired in parts made with high performance plastics. Gas assisted injection molding (GAIM/GIT) is one of the methods used to reduce weight of thick parts, thus maintaining a high strength to weight ratio. Before manufacture, the mechanical feasibility and strength are tested using state of the art FEM mechanical simulation programs. In GAIM/GIT parts, a major unknown factor that has to be taken under consideration for mechanical simulation is the gas core shape. The warpage and the fiber orientation also play important roles in the mechanical behavior of these parts. Thus, accurate prediction of the Gas core geometry, Warpage and Fiber orientation are essential. Process simulation software such as Autodesk Moldflow aids in the accurate prediction of these factors. This presentation will go in depth in analyzing the factors responsible for providing accurate process simulation results which would be used to build mechanical simulations. The results of these mechanical simulations are then compared with those of mechanical tests performed on mechanical parts that were manufactured with the same process setting.



Aniket Raje, Röchling Automotive SE & Co. KG (D)

Aniket Raje received his Bachelor's degree in Mechanical Engineering from Mumbai University in India. He gained his first industry experience in various internships and then continued his studies at Aalen University. After a further internship at BASF SE in Ludwigshafen, he wrote his master's thesis on "Simulation and Experimental Validation of the Production and Structural Mechanical Application of a Plastic Automotive Part in Gas Injection Process" at BASF SE and completed his studies at the end of 2018 with Master’s degree in Polymer Technology. Immediately afterwards he started as a CAE engineer at Röchling Automotive in Worms, where (amongst others) he is responsible for structural analysis, process simulation with Moldflow and simulation automation in Linux environments.


Interface strength of Overmolded Composites

Overmolding of thermoplastic composites is a technology in which a continuous fiber reinforced thermoplastic insert is thermoformed and subsequently overmolded using an injection molding process. The overmolding process allows for complex 3D structures with excellent structural performance and a high level of function integration, while still achieving high production rates.

One of the main concerns for structural overmolded parts is the strength of the interface between the continuous fiber reinforced composite laminate and the short fiber reinforced injection molding compound. The bond between the two domains is obtained by polymer interdiffusion, which is mainly temperature driven.

A model has been developed at the TPRC to predict the interface strength and a workflow has been set up to perform structural simulations on overmolded parts. An interface strength characterization study is being performed to link the simulated interface strength to mechanical test data via a failure model. The goal is to develop a validated virtual environment to determine the structural performance of overmolded structures and to develop design guidelines.



Coen Hartjes, Thermoplastic Composites Research Center (NL)

Coen Hartjes studied mechanical engineering at the University of Twente in Enschede. During this period, he participated in the solar car racing team, where his interest for composite materials started. He specialized in this subject during his master Mechanical Engineering and wrote his thesis on “Development of an interface strength characterization method for overmolded thermoplastic composites” during his graduation project at the ThermoPlastic composites Research Center (TPRC). He continued working at the TPRC as a researcher and lab operations coordinator. He focusses mainly on overmolding with the COMPeTE II project where, together with industrial partners, a software tool and knowledge are being developed to predict the performance of overmolded structures.