Moldflow Consulting Services

What The Madison Group does is simple. We solve plastics problems while keeping in mind your desire to drive product development towards lower costs and higher quality. We customize our services to deliver exactly what you need. In today's marketplace, time is of the essence. It is critical when designing plastic parts that one understands how the plastic will behave in the environment and the operational load to which it will be subjected. Our knowledge of plastic processing and Moldflow's technology ensure that your design and mold will work right the first time.

Use our online request form for a quote or call The Madison Group, (608)231-1907.

Fill/Pack Analysis

Fill/Pack analysis provides a comprehensive look at the resin during the critical injection and packing phase. The Madison Group can perform process capability studies that evaluate performance prior to mold construction. This analysis can yield information on:

Runner system design Molding optimization Material selection Gate positioning Pressure requirements

Tonnage requirements Weldline placement Gas trap locations Sink marks Molded-in stresses

Cooling Analysis

• The cooling phase is often the critical phase for determining cycle time. Analyzing the cooling phase can help determine what coolant conditions are needed to maximize the efficiency of the proposed cooling layout. High conductivity mold insert, and cooling components such as baffles and bubblers can be compared beforehand so that costly and difficult changes to the cooling system can be avoided. A cooling circuit analysis can assist in:

Cycle Time Optimization Optimized Coolant Conditions Selection of High-Conductivity Evaluation of Baffles and Bubblers Circuit Pressure Drops

Warpage Analysis

Warp can be related to several factors including part design, resin selection, fiber orientation, the molding process, or cooling system. Warp analysis isolates the reasons for part distortion after molding and create a solid foundation for making changes to reduce or eliminate the distortion. Using warp analyses we can assist in identifying design and process variations that cause warp, conduct material comparison, and identify potential distortion in critical areas.

Structural FEA To predict how a part will perform structurally while in the field, The Madison Group commonly uses structural finite element simulation. This software allows one to predict part response - stress distribution, deformation - when a load is applied to the part. Information extracted from these analyses enable us to determine critical structural areas. Such an analysis can lead to a solution that meets your performance and processing needs. The Madison Group has the experts when it comes to mold filling and structural finite element simulation of plastics. The phrase, "garbage in equals garbage out," holds very true for the analysis of plastics. The simulation process is not a plug and play operation. An appropriate model that accurately represents the part needs to be created; boundary conditions and processing conditions need to be understood and applied; and the right material properties for the simulation being conducted need to be used.