Using CAE simulation to optimize injection mold design
Gate at thickest section. Keep L/T < 100-150. Multiple gates cause weld lines.
Analyze at 10%, 50%, 90%, 100% fill. Monitor shear rate (max 40K-100K 1/s).
Cooling = 60-80% of cycle. Channel spacing: 2-3× diameter. Conformal cooling: 20-40% reduction.
Causes: differential shrinkage, orientation, uneven cooling. Fiber orientation: 2-3× anisotropic shrinkage.