moldflow

Moldflow is a family of computer-aided engineering software tools used to simulate the injection molding process for thermoplastic and thermoset polymers. Developed by Moldflow Corporation and subsequently acquired by Autodesk, the software enables engineers to predict how molten plastic fills a mold, cools, and solidifies, with the goal of identifying potential defects and guiding design and tooling decisions before physical prototypes are made.

The core of Moldflow is a finite-element/finite-volume solver that models polymer rheology, heat transfer, phase change, and mold cooling. Users input a CAD representation of the part and mold, select materials from a database, and specify processing conditions such as melt temperature, mold temperature, backpressure, injection speed, and packing pressure. The software outputs metrics such as fill time and velocity fields, air traps, weld lines, temperature distributions, solidification timing, shrinkage, and predicted warpage and residual stresses.

Typical uses include part design optimization, gating and runner design, venting, cooling channel layout, and process parameter studies to reduce cycle time and scrap. Moldflow supports features such as gas-assisted and hot-runner systems, and interfaces with common CAD tools and PLM workflows to facilitate design iterations.

History and variants: Moldflow originated as Moldflow Corporation; Autodesk acquired it and integrated it into its simulation toolbox as Moldflow Insight and related products. The tool has been used widely in automotive, consumer electronics, packaging, and medical device industries. Accuracy depends on material data and modeling assumptions; it is computationally intensive and results depend on mesh quality and user input.

Related topics include injection molding, finite element analysis, and computational fluid dynamics.