Process Simulation Integration in Product Design

The effect of processing parameters on the material properties is an important design consideration in plastic part design. The process may cause anisotropic properties due to matrix and fiber orientation, develop internal stresses during cooling, cause thickness variation etc. These effects if not considered in the product design and analysis, may result in premature product failure, reduced safety factor, fit and finish issues or higher costs and weight due to over design. Injection molded long glass polypropylene and blow molded PC/ABS have been used in automotive structural parts requiring to meet stringent static and dynamic loads as per the regulatory legislation. This paper demonstrates the use of injection molding and blow molding process simulation to incorporate the process effect on material and structure properties.