Manufacturing-Informed Design for Injection Over-Molding

Abstract

A fundamental tenant of materials engineering is the relationship between manufacturing, microstructure, and performance. Manufacturing simulation enables true performance prediction as well as tooling design and process design. This paper presents work completed on process simulation for an injection over-molded part emphasizing the need for manufacturing simulation to accurately predict performance. Accurate design for performance must consider the influence of manufacturing. Predictions of the injection over-molding process simulation for preform deformation, flow behavior, fiber orientations, effective properties, and dimensional stability are presented, and the implications on tooling and design process are discussed. Common concerns in injection over-molding manufacturing like weld lines, dimensional stability, interface temperatures, and air traps are all captured in the manufacturing simulations which will then inform design. The process simulation is connected to manufacturing and performance design, and a recommended process simulation workflow is presented.