Mold analysis

1. PTC CREO MOLD
ANALYSIS EXTENSION
(CMA)
Russell J.H. Hsu
Product Management Manager
July 2014

2. 2
• Current Process Challenges
• PTC Creo Mold Analysis Introduction
• Features and Benefits
• CMA product packages
• Appendix
– Moldex3D Product Portfolio
– Comparison to Moldflow Plastic Advisor
• Q & A
AGENDA

3. 3
Products and their
corresponding tooling are
getting more complex
CURRENT PROCESS CHALLENGES
Tooling Market Trends
• Teams, data and processes
span business and geographic
boundaries
• Need to be right the first time
with expected quality
• Need to formalize and reuse
design and manufacturing
knowledge
• Need early involvement with
customer
Tooling Design and
Manufacture
Relentless price erosion and
increasingly
shorter cycle-time
• Tooling is typically on the
critical path of any new
product introduction
• Need to respond very quickly
with accurate quote
• Massive pressure to reduce
tooling design and
manufacturing lead time
• Increased global competition
• Need to accept changes late in
the cycle
“ Mold and die shops identified price competition as their top business pressure …
… despite the fact that the products and the corresponding tooling is only getting more complex”
From “Aberdeen Group, The 21st Century Mold and Die Shop”, April 2007

4. 4
• Increased time to market
• Extensive mold debugging trials
• Costly mold rework
• Excess material usage
• Poor molded part quality
CURRENT PROCESS CHALLENGES
Lots of costs because plastics parts are not optimized for the injection molding process…

5. 5
PTC CREO MOLD ANALYSIS INTRODUCTION

6. 6
Validate Part Design
Check wall thickness
Confirm Moldability
Check potential weld
lines and air traps
Optimize Mold Design
Gate type & locations
Enhance cooling
Control warpage
Fiber Orientation
FEA validation
Molding Innovation
Ultra Precision products
Innovative process
Value-added process
• CMA is a new product to replace Creo Plastic Advisor in Creo 3.0 M010
• CMA provides injection molding process simulation for preliminary product design
– Rapid diagnostics of the feasibility of plastic injection molding
– Rapid diagnostics of the materials and injection conditions on the final result
PTC CREO MOLD ANALYSIS EXTENSION
What is PTC Creo Mold Analysis Extension (CMA)?

7. 7
• Allows customer to quickly and accurately analyze and optimize not just every design but every design
iteration
• Enables Design Engineers to gain insight into the Manufacturability of their Designs
– Will it fill?
– Where are the weld lines & air traps?
– Which material?
– Gate location?
– How to size geometry for optimal manufacturability?
PTC CREO MOLD ANALYSIS EXTENSION
Why PTC Creo Mold Analysis?

8. 8
• Intuitive, process-driven UI
– Quickly learn how to build molds leveraging process-driven UI
• Optimization of Plastic Part
– Determine potential part defects such as short shot, weld lines, air traps, and sink marks.
• Optimize Injection Molding
– Molding condition
– Gate location
• Injection Molding Simulation
– Quality Prediction
PTC CREO MOLD ANALYSIS EXTENSION
What does PTC Creo Mold Analysis provide?

9. 9
• Because of the high cost of injection molds (>>$10,000) and the low cost of Creo Mold Analysis, the
customer’s ROI can usually be achieved on one project.
• Allows customer to quickly and accurately analyze and optimize not just every design but every design
iteration directly from within Creo.
– Best CAD-integrated
– Provides unique on-line advice
– Extremely easy to use
– Extensible Solution Depth
PTC CREO MOLD ANALYSIS EXTENSION
How does the customer benefit?

10. 10
FEATURES AND BENEFITS

11. 11
• Fully integration with Creo
PTC CREO MOLD ANALYSIS EXTENSION
Intuitive, process-driven UI

12. 12
PTC CREO MOLD ANALYSIS EXTENSION
Animates plastic injection fill process
100% Display80% Display
60% Display30% Display

13. 13
PTC CREO MOLD ANALYSIS EXTENSION
Comprehensive database of common plastic materials

14. 14
PTC CREO MOLD ANALYSIS EXTENSION
Automatically apply optimized process condition according to selected plastic material

15. 15
PTC CREO MOLD ANALYSIS EXTENSION
Identify optimal injection locations
Single gate
Two gates

16. 16
PTC CREO MOLD ANALYSIS EXTENSION
Identifies potential mold filling problems
Air Trap Weld Line

17. 17
Short shot
PTC CREO MOLD ANALYSIS EXTENSION
Identifies potential mold filling problems
Hesitation

18. 18
PTC CREO MOLD ANALYSIS EXTENSION
Provides appropriate resolutions for the potential issues

19. 19
PTC CREO MOLD ANALYSIS EXTENSION
True 3D Solid solvers, more accurate result
Dual Domain Technology(2.5D) True 3D solver
Disconnected

20. 20
PTC CREO MOLD ANALYSIS EXTENSION
• Features
– Animates plastic injection fill process
– Access library of common plastic materials
– Automatically apply optimized process condition according to selected plastic material
– Identify optimal injection locations to reduce cycle time and improve product appearance
– Identifies potential mold filling problems such as short shots, air traps, weld lines
– Automatic reporting Tools
– Provides appropriate resolutions for the detected failures
• Benefits
– Fully integrate with Creo Parametric
– Easy-to-use User Interface
– True 3D Solid solvers, more accurate result
– Improve design quality and reduces manufacturing cycle times and rework of molds
– Designed as a tool for non-specialists without need for training in abstract concepts
– No data translation between CAD, CAM, CAE
Summary

21. 21
CMA PRODUCT PACKAGE

22. 22
• PTC Creo Mold Analysis
– A product package with full functionality.
– Complete Flow and partial Pack simulation
• PTC Creo Mold Analysis Foundation (Free version)
– A light version of PTC Creo Mold Analysis
– Free for all Creo users
– Limited functionality (Melt Front Time only)
PTC CREO MOLD ANALYSIS EXTENSION
CMA Product Packages

23. 23
APPENDIX
MOLDEX3D PRODUCT PORTFOLIO

24. 24
MOLDEX3D PRODUCT STRUCTURE
Structure and Market Position
eDesign Basic
CMA
Creo
eDesign
eDesignSYNC
Creo

25. Design Verification and
PLM Integration
Optimized Part
Designs
Productivity
Sophisticate process
Multi-Component Molding
Fiber Orientation
Valve gate control
Advanced hot runner
Conformal cooling
Product Life Cycle Efficiency
HPC / Remote Computing
Cooling time reduction
Accuracy
Sensor and measurement
Powerful post-processing tools
Quality
Warpage prediction
Identify flow balance
Identify residual stress
Material degradation
Shrinkage prediction
Tooling Validation
Clamping force
Multi-Cavity flow balance
Runner balance
Injection pressure
Packing pressure

26. 01
Flow
Everything starts
from filling analysis
02
Pack
Shrinkage compensation,
minimize warpage effect
03
Cool
Efficient mold
temperature
management
04
Warp
Minimize part
deformation
for design accuracy
MCM
Precise multi-
component
molding analysis
Fiber
Predict fiber length and orientation to
obtain optimal designs and process
conditions
High Performance Computing
(HPC)
Enable parallel computing and cluster
speed up the analysis process

27. 27
APPENDIX
COMPARISON TO MOLDFLOW PLASTICS
ADVISER

28. 28
PTC CREO MOLD ANALYSIS VS. PLASTIC ADVISOR
PTC Creo Mold Analysis Plastic Advisor (Moldflow)
Mesh preparation Automatic full 3D mesh generation Dual Domain (DDT) mesh. Manual mesh
density adjustments are necessary
CAD supports STL or boundary mesh STL or boundary mesh
Solver True 3D solvers Performing 2D analysis on opposite
surfaces then synchronized artificially
Speed Moldflow is generally faster as it’s 2.5D
Accuracy CMA is more accurate as it’s 3D. Strange melt front can be predicted by
Moldflow/Fusion if the part geometry is complex.
Fiber CMA is more accurate as fibers usually show strong 3D orientations
Warp PTC Creo Mold Analysis is more accurate as it’s 3D
General comments  Dual Domain technology only excels if the part has uniform thickness and
very few ribs/bosses.
 More and more products are designed with very variable wall thickness. It’s
essential to run 3D analysis on most parts.
 PTC Creo Mold Analysis is more accurate when integrating with structural
analysis, especially for fiber-filled materials.

29. ptc.com