In this economic climate, it is critical to create higher quality processes and parts while keeping costs as low as possible. This typically means getting analysts involved in the beginning phases of a project. Spending less money up front with analytical work saves both time and money on potential costly tool re-work at the end of a project.
Because of the high costs of tooling rework, more and more businesses are turning to analysts for in-depth knowledge before, during, and after the course of their project. Whether the analyst is internal or is a hired consultant, it is extremely important to know what experience and knowledge your analyst has in order to take full advantage of their expertise.
In the injection molding environment there are several types of analysts used, i.e. structural, polymer flow, etc. Having an analyst that knows their job is an absolute necessity. In order to have a comprehensive understanding of their job, analysts must be knowledgeable in all aspects of the injection molding process.
Let's discuss, what should be, some basic requirements a Polymer Flow Analyst (example: Moldflow) should have for analyzing the injection molding process.
Plastics Knowledge:
Without discussing much more, the first question that comes to mind:
Is the analyst a Plastics Engineer or will a Plastics Engineer be involved?
Without a full understanding of polymers, it is extremely difficult to understand polymer behavior during processing. This knowledge begins at a molecular level and extends far beyond standard processing knowledge. A Plastics Engineer is able to understand the differences between polymers and each polymer's flow characteristics. This can be used in conjunction with the simulation software to optimize the analyzation process. It is crucial to have a Plastics Engineer involved with plastics processing.
Injection Molding Experience:
A flow analyst is typically required to identify and understand polymer flow behaviors within the injection mold. This can, most times, involve analyzing the 1st stage, 2nd stage, and cooling stages of the injection molding process. If your analyst must study these phases of the injection molding process, it is extremely important that they have a FULL understanding of the injection molding process. ---- In other words, have they ever run an injection molding machine or been formally trained on one? Does he/she understand thermolators/chillers? Without injection molding experience, it is difficult to properly analyze such a process.
Mold Design:
A flow analyst is sometimes required to make design recommendations or changes to a mold to further optimize a process. In order to understand how to suggest making such changes, it is vital that they are trained in mold manufacturing and design. Sometimes a change cannot be made due to cooling line or ejector pin interference. Perhaps there is 'action' (slides) within the tool that would prohibit such changes. There are many other examples that could be cited, but the point has been made. This understanding of mold and tool design is critical in order to properly optimize a mold.
Because analysts are becoming more integral in lower cost, high quality processes, it is important to understand who your analyst is and what experience they are truly bringing to the table. It is also important to know if they have any formal training and/or floor experience. The more skills your analyst brings to the project, the more successful your project will be in meeting or exceeding its expectations.
Contact Bozilla Corporation for your FEA and injection molding troubleshooting needs. We invite you to visit our website at
www.BozillaCorporation.com. 
