Computational tools for the optimal design of the injection moulding process

Abstract In the present paper a computer simulation tool, the NASPLAN code, is presented towards the intelligent design of the injection moulding process in complex and multicavity moulds. Furthermore, the NASPLAN code has been coupled with three different numerical optimisation methods in order to design the guidance of melt either by tuning the gates’ geometry optimally or by introducing appropriate vacuum at specific areas. This procedure leads to flow balancing and improved part quality by minimising flow-generated defects such as warpage, non-uniform shrinkage, sink marks, etc. Furthermore, the use of vacuum results in faster filling stage with lower injection pressure requirements. Finally, three test cases have been studied to demonstrate the effectiveness and the usefulness of the proposed methods.