Achieving Tooling Success Through Finite Element Analysis

The engineers at Hi-Tech Plastics and Molds use creative genius and scientific molding to execute your design successfully, from art to production part. Utilizing methods like Finite Element Analysis helps our engineers achieve 1^st Generation tooling success for intricate designs.

A manufacturing client conceptualized a plastic molded part for bindings while skiing at California’s Mammoth Mountain Ski Area during their Christmas holiday break in 2010.  They knew the disc needed to be durable and made to precise tolerances, and from materials exhibiting the right properties for strength and cold weather resistance.

The Challenge: Mold Design for Ski Binding Parts

After creating a preliminary drawing, the client tried creating a mold thick enough for their part but was unsuccessful. They contacted Hi-Tech for assistance and submitted their 3D drawing to us for review.

The Solution: Scientific Molding & Engineering

The engineering team at Hi-Tech takes all the necessary steps to get the right outcome on 1^st generation tooling.  This product’s scientific molding process involved multiple rounds of finite element analysis and 3D simulation before cutting the steel into molds.

• Step 1: We applied Finite Element Analysis “FEA” to 3 iterations of design. This process helped us determine which result would be the optimum 1^st generation design theoretically.
• Step 2: Another round of Finite Element Analysis helped find stresses in the design, confirm optimum part geometry, and determine material selection before designing the mold.
• Step 3: Our Design for Manufacturability phase included 3D modeling and complete Mold Optimization simulation studies using Autodesk Moldflow Insight.  The objective was to evaluate the filling pattern and optimize the cooling layout to provide uniform temperature and minimize warpage.
• Step 4: The engineering team used scientific molding studies to validate the theoretical design. Through this process, we optimized processing parameters and narrow the numerous options. Scientific molding helps us achieve a best-case outcome with 1^st generation tooling before mold production begins.

Finite Element Analysis of Part Stress After Molding with Specific Gate Location

Phantom lines on the drawing provide additional clarity in the location of the highly stressed areas. The dark blue regions of the part are a good indication of where material may be removed by coring if a weight reduction is desired in the part under these conditions. 

Complete Mold Optimization Study Using Autodesk Moldflow Insight

This plot shows how shrinkage differences in the part affect the warpage. Based on the scale, the analysis shows the shrinkage differences from the perimeter of the part to the center have an impact on the part warpage.

This plot shows how shrinkage differences in the part affect the warpage. Based on the scale, the analysis shows the shrinkage differences from the perimeter of the part to the center have an impact on the part warpage.

The Results: Prototype Testing & Product Launch