Case Studies Rapidmade/Portland State University Advancing Injection-Mold Technology Research with Solidworks Solutions

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	Rapidmade/Portland State University Advancing Injection-Mold Technology Research with Solidworks Solutions

Rapidmade/Portland State University Advancing Injection-Mold Technology Research with Solidworks Solutions

Technology Category	Analytics & Modeling - Predictive Analytics Analytics & Modeling - Real Time Analytics Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Plastics
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Manufacturing System Automation Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	Conformal cooling channels, which uniformly cool injection molds and the plastic parts inside, have long represented the ultimate productivity goal in injection-molding manufacturing. Cooling channels that conform exactly to the geometry of the injection-molded part would make quick, uniform cooling of the molded plastic possible, resulting in better quality parts, faster cycle times, decreased part waste, and reduced energy consumption. To date, conformal cooling channels have remained just a research idea because the traditional techniques used to machine molds, such as milling and drilling, are incapable of producing all of the geometric shapes required. However, a team of researchers from Portland State University (PSU) and RapidMade, a 3D printing, manufacturing, and engineering company based in Portland, Oregon, have secured a federal grant to conduct research and development aimed at determining how to bring conformal cooling channels to the injection-molding industry. Read More
About Customer	RapidMade is a 3D printing, manufacturing, and engineering company based in Portland, Oregon. The company specializes in leveraging advanced manufacturing technologies to create innovative solutions for various industries. In collaboration with Portland State University (PSU), RapidMade is working on a federally funded research project to develop methods for implementing conformal cooling channels in plastic injection mold cores using additive manufacturing tooling. The research team includes PSU student and Team Lead Christopher Mullens, PSU Computer Science Associate Professor Bart Massey, and RapidMade Engineering Director David Shapiro. Their goal is to advance the injection-molding industry by creating molds with conformal cooling channels, which would result in better quality parts, faster cycle times, decreased part waste, and reduced energy consumption. Read More
Solution	The research team chose SOLIDWORKS® injection-molding solutions, including SOLIDWORKS Professional design, SOLIDWORKS Simulation Premium analysis, SOLIDWORKS Flow Simulation computational fluid dynamics (CFD) analysis, and SOLIDWORKS Plastics Premium injection-molding simulation and analysis software. These tools were selected for their adaptability and comprehensive capabilities in CAD, simulation, and plastics injection-molding. The process begins with the creation of a plastic part, from which the mold and cooling channels are modeled using SOLIDWORKS Professional software. The design is then taken into SOLIDWORKS Plastics Premium to evaluate how molten plastic flows into the mold and to optimize the mold design with respect to material flow and cooling channel placement. SOLIDWORKS Flow Simulation is used to analyze how effectively the flow of liquid coolant in the cooling channels cools surrounding walls, and SOLIDWORKS Simulation Premium software supports analyses of the thermal effects of the cooling channels throughout the mold. Simulation findings help guide modifications and support design iterations. The combination of SOLIDWORKS Plastics Premium, SOLIDWORKS Simulation Premium, and SOLIDWORKS Flow Simulation software enables the team to more efficiently and effectively study the interaction of molten plastic and cooling channels in virtual molds. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Analytics & Modeling - Real Time Analytics

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Plastics

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

Conformal cooling channels, which uniformly cool injection molds and the plastic parts inside, have long represented the ultimate productivity goal in injection-molding manufacturing. Cooling channels that conform exactly to the geometry of the injection-molded part would make quick, uniform cooling of the molded plastic possible, resulting in better quality parts, faster cycle times, decreased part waste, and reduced energy consumption. To date, conformal cooling channels have remained just a research idea because the traditional techniques used to machine molds, such as milling and drilling, are incapable of producing all of the geometric shapes required. However, a team of researchers from Portland State University (PSU) and RapidMade, a 3D printing, manufacturing, and engineering company based in Portland, Oregon, have secured a federal grant to conduct research and development aimed at determining how to bring conformal cooling channels to the injection-molding industry.

About Customer

RapidMade is a 3D printing, manufacturing, and engineering company based in Portland, Oregon. The company specializes in leveraging advanced manufacturing technologies to create innovative solutions for various industries. In collaboration with Portland State University (PSU), RapidMade is working on a federally funded research project to develop methods for implementing conformal cooling channels in plastic injection mold cores using additive manufacturing tooling. The research team includes PSU student and Team Lead Christopher Mullens, PSU Computer Science Associate Professor Bart Massey, and RapidMade Engineering Director David Shapiro. Their goal is to advance the injection-molding industry by creating molds with conformal cooling channels, which would result in better quality parts, faster cycle times, decreased part waste, and reduced energy consumption.

Solution

The research team chose SOLIDWORKS® injection-molding solutions, including SOLIDWORKS Professional design, SOLIDWORKS Simulation Premium analysis, SOLIDWORKS Flow Simulation computational fluid dynamics (CFD) analysis, and SOLIDWORKS Plastics Premium injection-molding simulation and analysis software. These tools were selected for their adaptability and comprehensive capabilities in CAD, simulation, and plastics injection-molding. The process begins with the creation of a plastic part, from which the mold and cooling channels are modeled using SOLIDWORKS Professional software. The design is then taken into SOLIDWORKS Plastics Premium to evaluate how molten plastic flows into the mold and to optimize the mold design with respect to material flow and cooling channel placement. SOLIDWORKS Flow Simulation is used to analyze how effectively the flow of liquid coolant in the cooling channels cools surrounding walls, and SOLIDWORKS Simulation Premium software supports analyses of the thermal effects of the cooling channels throughout the mold. Simulation findings help guide modifications and support design iterations. The combination of SOLIDWORKS Plastics Premium, SOLIDWORKS Simulation Premium, and SOLIDWORKS Flow Simulation software enables the team to more efficiently and effectively study the interaction of molten plastic and cooling channels in virtual molds.

Impact #1	The research team developed a workflow automation path for using SOLIDWORKS solutions to drive additive manufacturing techniques to create conformal plastic injection-mold cooling channels.
Impact #2	The combination of SOLIDWORKS Plastics Premium, SOLIDWORKS Simulation Premium, and SOLIDWORKS Flow Simulation software enabled the team to study the interaction of molten plastic and cooling channels in virtual molds more efficiently and effectively.
Impact #3	The team can now optimize the part and the mold, study how plastic cools over time, specify mold wall temperature as a simulation input, and assess the eddies and shear in the flow of molten plastic in an integrated modeling environment.

Impact #1

The research team developed a workflow automation path for using SOLIDWORKS solutions to drive additive manufacturing techniques to create conformal plastic injection-mold cooling channels.

Impact #2

The combination of SOLIDWORKS Plastics Premium, SOLIDWORKS Simulation Premium, and SOLIDWORKS Flow Simulation software enabled the team to study the interaction of molten plastic and cooling channels in virtual molds more efficiently and effectively.

Impact #3

The team can now optimize the part and the mold, study how plastic cools over time, specify mold wall temperature as a simulation input, and assess the eddies and shear in the flow of molten plastic in an integrated modeling environment.

Benefit #1	Won a federal research grant.
Benefit #2	Laid the groundwork for increasing injection-molding productivity.

Benefit #1

Won a federal research grant.

Benefit #2

Laid the groundwork for increasing injection-molding productivity.

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Overview

Rapidmade/Portland State University Advancing Injection-Mold Technology Research with Solidworks Solutions

Operational Impact

Quantitative Benefit