How to save energy, cost, and make competitive products?

How to save energy, cost, and make competitive products?
Polymer processing industry has evolved dramatically during the last decade. Several new technologies
were developed in order to improve product quality and save manufacturing cost. Energy topics are still
hot these days since its shortage and price are increasing, not mention the impact of the environment
such as global warming. That is why carbon foot print standard was regulated now. The newly developed technologies in injection molding are highly related to environmental concerns such as hot
runner, conformal cooling, and variotherm – each one has been widely used nowadays. In this seminar,
we will briefly talk about the developing trends in polymer process. Then, each of the three topics will
be discussed in details individually.
1. Conformal Cooling
Cooling is a critical issue in pursuing high quality product in injection molding process. The concept
from rapid prototyping had been now transformed to mold tooling. Conformal cooling is a technique to
eliminate hot spots and product defects. This course will begin with the concept and theory of mold
cooling – the difference between conventional and conformal cooling will be discussed. The manufacturing methods (Fig. 1) and benefits of conformal cooling will then be introduced. In order to find out
potential issues or confirm parameters in cooling designs, a CAE simulation technique for conformal
cooling is introduced. CAE results can unveil how the designs affect process and product quality. New
functions in Moldex3D will be briefly discussed. Finally, real cases (Fig. 2) were studied for the effectiveness of conformal cooling. It indicates that conformal cooling can shorten cycle time, improve product
quality, and save manufacturing costs.
Fig. 1 Laser Sintering Machine (left) and its process (right)
Fig.2 Conformal cooling real case study
2. Hot runner
Hot runner technology has been applied to many injection products from large-sized parts (bumper,
LCD panel front/back cover etc.) to small-sized parts (bottle cap, optical component etc.). It replaces
traditional cold runner to solve some molding issues such as weld lines and product surface problems.
And most importantly, it can save plastic material use and help protect our earth.
However, a hot runner system is relative expensive and its mechanism is very extensive and mysterious.
In this section, we will start from a short introduction of hot runner systems. The second part will talk
about some important issues such as flow imbalance, dead spot, non-uniform heating, and degradation. Then some cases (Fig. 3) will be discussed to show how to utilize CAE to revise design, improve
quality, and save energy. With the advanced hot runner simulation from Moldex3D, temperature distribution can be estimated in 3D and transient. Effects from each component within a hot runner system
can be considered to achieve better accuracy.
3. Variotherm
Fig.3 Hot runner real case study
Plastic product surface problem is always annoying – weld lines, surface gloss, fiber exposure…etc.
Variotherm is a method applied in some of the most popular applications such as ultra-book dimension
control and enhancing the replication of micro injection molding. This is a technique by controlling
mold temperature at different time and space in the mold. There are various methods in this category,
including RHCM (Rapid Heat Cycle Molding), E-mold (Electricity Mold), IHM (Induction Heating Mold),
IR heating, and so on.
In this last section, a short introduction of variotherm will be addressed which followed by the benefits
and common applications of this technology. The second part of this course will talk about CAE and its
use on simulating variotherm technology. True 3D transient cool technology is used to have insight into
the mechanisms of variotherm technologies. Some case studies (Fig. 4) will be discussed to show how
to get the best benefits from simulation. Again, it is another important “Green Molding“ technology
which can save the cost make your product more competitive.
Fig.4 Variotherm real case study
Date & Location:
関東 Kanto
名古屋 Nagoya
大阪 Osaka
㈱ セイロジャパン
CoreTech System Co., Ltd. (Moldex3D)
13:00 ~ 13:20
13:20 ~ 14:30
14:30 ~ 15:40
15:40 ~ 15:50
15:50 ~ 17:00
17:00 ~ 17:10
Current Trends in Injection Molding
Conformal cooling
Hot runner
Enterprise owners
Engineers (RD、Manufacturing、Product design、Mold design etc.)
Mold manufacturers
Material suppliers
Academic researchers
Whoever interested in advanced plastic process manufacturing
Expected Learning Goals:
Learn the latest trends in green molding industry
Understand the differences between conformal and conventional cooling.
How to use CAE to help validate cooling system design and get the maximum benefits.
Understand the hot runner system and how to use CAE to simulate a real
hot runner system.
Realize different variotherm methods and theories. Know how to use CAE to
simulate a variotherm process.
Professional Instructor:
Dr. Fu-Hung Hsu
Current position: CoreTech System Project Manager
Education: Ph.D. of Mechanical engineering in University of California, Davis.
Research area: Aerodynamics, heat transfer, numerical analysis, advanced
injection molding process.
Dr. Hsu has several years teaching and research experience in professional
engineering fields such as heat transfer, experimental method, and injection
molding. After attaining his Ph.D. in University of California, Dr. Hsu joined
CoreTech System in 2010, he continued his research in CAE and several
advanced injection molding fields such as gas/water assisted injection mold,
conformal cooling, optical parts, hot runner system, and variotherm technology. Dr. Hsu has assisted some famous injection molding manufacturers to
solve real industry cases worldwide. His teaching style combines theories
and practical cases which offer a thorough understanding for both novice
and experienced professionals.
Event Contact:
セイロジャパン 関東営業所
〒344-0065 埼玉県春日部市谷原3-1-8マルヤビル
TEL:048-733-7011 FAX:048-733-3268
Ms. Rachel Wu
[email protected]