DESMA SMARTFLOW OPTIMIZES MOLD DESIGNS
SmartFlow software and analysis are unique to DESMA due to material characterization and injection unit data incorporated in mold flow calculations.
Traditional mold designs try to keep cavity numbers even and runners symmetrical and equal in length to give molds the best shot at optimal balance from the start. However, there are certain instances in which our design team will be tasked with designing a mold with an odd number of cavities or an odd number of decks, and sometimes the article itself has an irregular shape that does not lend itself very well to packing out thoroughly with elastomer during part injection. Balancing an odd number of cavities is always a challenge.
In these instances, DESMA utilizes our SmartFlow software to prove the mold design concept and catch any issues the flow analysis model data may illustrate. SmartFlow calculations may prove the design concept immediately. The data from SmartFlow could also indicate the need to increase the size of the runners or the gate depth, decrease the amount of runners, or which locations to add vents to prevent air entrapment during article injection. DESMA uses SmartFlow analysis data to lead the way to optimize the mold design during the CAD phase. Catching issues in the CAD phase is always the most cost-effective method before cutting anything into steel. Optimizing the mold using this data leads our customers to a broader process engineering envelope throughout the life of the mold.
The SmartFlow analysis process starts with our design engineers creating a complete 3D mold in Siemens NX software. Additionally, our designers will create a complete elastomer model that includes everything from the point of injection through the sprue, runners, gates, and ultimately completely filled articles and overflow grooves. We then export this NX 3D model to a raw CAD data file to be imported into our mold flow analysis software. The SmartFlow engineer will then assign a material to the elastomer from our material library. DESMA can also send out customer-supplied material for chemical analysis to assign the exact formula the customer runs to the elastomer model. Our SmartFlow engineers will then set a running temperature gradient to the mold, set the software and run hundreds of injection simulation cycles. Using this data, engineers then fine-tune the design and rerun the simulation cycles until satisfactory results are achieved. To learn more about NAMC visit our page here: NAMC – COLD RUNNER AND MOLD PRODUCTION IN NORTH AMERICA