Case Studies
Drop by Drop
Plastic Innovation GmbH is taking a new approach to the economical and sustainable development of bicycle frames with carbon fiber-reinforced plastics. In the conception of functionally integrated and injection mold-ing-appropriate designs, SimpaTec supports the company with up-to-date simulation expertise. The frame of the first fully functionable demonstrator, an e-bike with a challenging low-entry design is manufactured fully automatically in a cycle time of 90 s by the WAIM method.
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High Gloss – Paintless and Painless
Skillful application of the evaluation and analytical options afforded by process simulation, including designing the best temperature-control system and making comparisons with alternative manufacturing processes, smoothes the way to efficient product development and manufacturing. Doing this from the very start of a project enables investments to be weighed and qualified, and technical, economic or environmental concerns to be taken into account, as exemplified here by a part with a high-gloss surface.
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Holistic virtual product development - Traditional concepts meet micromechanical approaches
The question is at which point a cycle begins. A cycle that has existed for many years in the context of virtual product development and has been customly accepted. But is this the right question? If we question this approach, new aspects consequently arise. For example, whether existing, previously proven mechanisms can or must be supplemented or extended in order to achieve set goals, perhaps even to exceed them, and if so, how?
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More is less
Making the production of optical lenses economical while maintaining a certain level of product quality poses a huge challenge. Aside from the need to modify the geometry of the molded part, there is often a debate about the right production strategy. Injection compression molding may offer an alternative to injection molding in terms of quality, but it is also cost-intensive. This is where simulation can serve as a decision-making aid.
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Crafty simulation – creative design
In many areas, when developing plastic components, almost every process and every mold or die is optimized in advance with the aid of simulation tools. But when it comes to thermoforming simulation is still used quite infrequently. Compared to using prototype tooling, however, software tools can save both time and money.
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Crease-free components
In the production of its irons, the renowned manufacturer Rowenta relies on tool technology with near-contour cooling from Werkzeugbau Hofmann. This has significant advantages like less installation effort, better part quality and shorter cycle times.
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Production of complex copper components by means of metal powder injection molding
Ulm-based Wieland-Werke AG has already introduced a new kind of technology in metal injection molding (MIM) for complex-shaped components made of copper alloys, which enable many design freedoms and a more economical production.
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Innovative pioneering work - precise and imaginative
Absolute precision and the best quality - this is Leonhardt’s company philosophy. Especially exceptional is the product range and the processing technologies used.
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Multi-component systems - innovative combination of different materials
By combining different materials into one component, various properties, such as electrically conductive/insulating, opaque/transparent or hard/tough, can be implemented at relevant points.
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Minimized core misalignment in the production of syringe bodies
With the use of Moldex3D, technological issues relating to the development, design and verification of medical devices can be solved easily, quickly and efficiently.
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Gating balance in multiple cavity tools
Many plastic components are manufactured in multiple cavity tools. This goes hand in hand with the problem of unbalanced filling. In Moldex3D, not only the cavity, but also the gating system is meshed with volume elements.
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