Computer-aided design of plastic micro injection mold

Engineers should incorporate the use of computer aided analysis software, commonly referred to as CAE analysis (using moldflow), to run flow simulations on micro and nano molded parts to verify the design and processability of the product. At this point, data is observed to determine proper filling of the cavity, locating potential air traps, and ensuring that weld/ knit lines won't form in critical areas, which can reduce the structural integrity by as much as 80%—the nominal strength of the part. Moldflow allows analysis of values such as shear rate, shear stress, and residual stress, which are highly important factors in the processing of a quality thin-walled part. Engineers use a set of process parameters in their simulations such that residual stress is minimized. Residual stresses in molding cause deformation as the melted material gets solidified too quickly and then tries to relax to its previous size. This is usually characterized by injecting the material too fast, followed by a rapid cooling cycle.