by Synergy Molding Technologies
The following article initially appeared on Synergy Molding Technologies’ Printjection Blog.
At Synergy Molding Technologies, LLC, we are committed to pushing the boundaries of what’s possible in injection molding through the innovative use of 3D printed tooling. Our expertise is amplified by our strategic partnerships with Cognitive Design Systems (CDS) and SimForm (Maya HTT). These collaborations allow us to leverage advanced simulation software to optimize the design, manufacturing, and performance of our 3D printed molds, ensuring the highest levels of efficiency and precision for our customers.
The Process: From Part Data to Optimized Tooling
Our journey begins with receiving customer part data, the foundation upon which we build every successful project. Once we have this molded plastic part data, our team rapidly generates lightweighted mold data using Cognitive Design Systems' advanced Cognitive Design software. This tool allows us to efficiently create complex mold structures that are optimized for 3D printing, significantly reducing both material usage and production time.
Simulating Perfection with SimForm
Next, we integrate this tool data into SimForm, a powerful thermal simulation software developed by Maya HTT. SimForm enables us to simulate the injection molding process, predicting critical factors such as hot spots within the mold. By analyzing these simulations, we can strategically place conformal cooling channels—designed to cool the molten plastic uniformly and rapidly—exactly where they are needed most.
Enhancing Mold Design with Precision
The journey doesn’t stop there. After gathering thermal data from SimForm, we loop the information back into CDS’s Cognitive Design software. Here, we meticulously trace the hot spot locations identified during the simulation and refine the placement of conformal cooling channels within the mold data. This step ensures that every cooling channel is optimally positioned for maximum effectiveness.
Once the refined mold data is complete, our expert designers take over. They further enhance the tool for manufacturing (DfM) by optimizing the lattice structure, wall thicknesses, and features intended to improve the turbulent flow of cooling water. This attention to detail ensures that our molds are not only functional but also exceptionally efficient.
Predicting Success with Extreme Accuracy
Before finalizing the design, we upload the completed mold data into SimForm one last time. This final simulation predicts the cycle time improvement we can achieve with extreme accuracy, providing our customers with a clear expectation of performance gains.
Conclusion
Through the strategic combination of Cognitive Design Systems' and SimForm's simulation software, Synergy Molding Technologies is able to offer unparalleled precision and efficiency in the design and production of 3D printed molds. Our approach not only reduces production costs and cycle times but also delivers molds that perform at the highest levels, even under the most demanding conditions.
Whether you’re in defense, automotive, consumer goods, or any other industry requiring high-quality injection molded parts, Synergy Molding Technologies has the expertise and the tools to bring your projects to life with unmatched precision and speed.
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