Rheological and Mechanical simulation services

In this initial phase, we design the optimal injection setup using simulation tools such as Moldflow, Moldex3D, and ProCast.

Based on the input data—CAD files, material type, and project requirements—we define the key mold parameters (injection system, part and gate positioning) to ensure:

• Uniform filling – Avoid short shots, hesitation zones, overpressure, and imbalances.
• Consistent pressure – Minimize pressure gradients to achieve uniform density.
• Reduced weld lines – Improve both part aesthetics and mechanical strength.
• Machine compatibility – Adjust clamping force to match the specifications of the selected injection molding machine.
• Warping control – Predict and reduce part deformation to ensure high dimensional accuracy.

This phase provides a solid foundation for a robust, high-quality injection molding process.

In this phase, we evaluate and optimize the mold cooling system to ensure efficient thermal control, promoting dimensional stability of the parts and improving production cycle time efficiency.

The main objectives include:

• Effective heat dissipation – Detection and prevention of hot spots by optimizing cooling channels and introducing baffles, thermal pins, etc.
• Faster cycle times – Balancing reduced cycle time with the required part quality to maximize efficiency.
• Temperature uniformity – Preventing warpage and internal stresses by maintaining consistent mold temperatures.
• Design compatibility – Aligning thermal performance with the material and geometry of the part.
• Energy efficiency – Reducing energy consumption without compromising results.

We also perform simulations with inserts and/or moving components made of special alloys (such as copper, AMPCO, MOLDMAX, etc.) to predict thermal transfer efficiency and assess the impact on cycle time reduction and final part quality.

When part defects and production issues occur and factory tests are inconclusive, we simulate real production conditions using Moldflow/Moldex3D to identify root causes and find solutions.

This includes:

• Root cause analysis – Replicating actual process conditions to reproduce observed defects in the simulation software, such as warpage, weld lines weakening critical or visible areas, uneven filling, high pressures, or short shots. After identifying the scenario, we simulate possible corrective solutions.
• Process optimization – Adjusting injection speed, pressure, temperature, and cooling time.
• Material evaluation – Verifying material compatibility with the mold and process.
• Mold adjustments – Modifying mold design or cooling system to resolve recurring issues.
• Validation – Repeating tests to confirm defect resolution and process stability.

At PRINEMO, we go beyond conventional injection molding by offering analyses and simulations for unconventional techniques. These methods enable efficient production of complex, high-quality parts.

Our expertise includes:

• Gas/Water-Assisted Molding: Simulation of controlled filling with pressurized gas or water, reducing weight and material usage without compromising mechanical strength or surface quality.
• Core Shift Analysis: Prediction of core displacement to ensure precise alignment and dimensions.
• Multi-Shot & Overmolding: Analysis of multi-material injection to add functionality and aesthetic value.
• Foaming and Weight Reduction Processes: Simulation of techniques like MuCell to reduce weight while maintaining structural integrity.

By integrating these unconventional process analyses into your project, we help innovate and refine manufacturing techniques, ensuring excellent results even with the most complex geometries.

At PRINEMO, we perform mechanical and structural analyses to predict and ensure maximum performance, reliability, and durability of parts and products.

Our services include:

• Structural Integrity Analysis – Assessing strength and stability under various load conditions.
• Finite Element Analysis (FEA) – Simulating stresses, strains, and displacements under real operating conditions.
• Fatigue and Durability Analysis – Predicting failure points and estimating product lifecycle.
• Impact and Collision Simulations – Optimizing critical designs for safety against high-energy impacts.
• Thermal and Vibration Analysis – Evaluating performance under thermal changes and dynamic loads.

These analyses enable us to develop robust, high-performance products, even for the most demanding applications.