Molex3D MuCell simulates addition of gas bubbles into plastics moulding for lighter parts

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The controlled addition of bubbles to injection moulded parts – like in a chocolate bar – can now be simulated in MuCell, reducing part weight while retaining structural strength

Inspired by the honeycomb structure of a chocolate bar, Moldex3D reports that its customers are using its MuCell technology to produce lighter parts by introducing gas bubbles into plastic parts as they are moulded.

Now MuCell’s simulation feature can help users achieve targeted weight reduction before actual manufacturing, reducing effort of testing different injection moulding ‘VP switch-over points’.

One of the strengths of this technology is that it lets users achieve a lightweight design without compromising too much on the mechanical strength of the part.

Setting the weight loss percentage from the weight of a solid part

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In the MuCell process, users could previously manually adjust and test the location of the screw in the injection moulding machine to control materials injected into the mould to achieve the targeted weight reduction before actual manufacturing.

In the previous simulation scenario, CAE engineers could only use trial-and-error, but now Moldex3D has introduced features that enables CAE engineers to set their targeted weight reduction ratio directly in a CAE simulation mode, helping time to market.

Users input the weight of the solid plastic part (including the runners’ weight) when setting the parameters; select the Shot weight percentage, and from there a fixed weight reduction ratio can be locked in without the same level of trial and error.

After a fixed weight reduction ratio is locked in, Moldex3D automatically monitors the cavity weight at every time step. When the cavity weight reaches the targeted weight, the melt injection is stopped. As shown in the image below – the part was set for an 8 per cent weight reception – the final weight of the solid plastic part is 65.23 grams (with a packing time of five seconds), and the final weight of theMuCell product is reduced to 60.39 grams, a weight reduction of 7.4 per cent.

Reducing the part weight by 8 per cent


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