The Complete Guide to Injection Molding Simulation Software

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Injection molding stands as the foundation of the manufacturing world, revolutionizing the production of parts across a myriad of industries. This method, known for its efficiency and versatility, shapes the way products are created, from everyday household items to intricate components in specialized fields. 

With Simulation softwares, injection molding is now a revered manufacturing technique for its precision and scalability. This production method has become indispensable in modern production processes. 

Simulation software is now a critical tool in mold design for plastic injection molding. By enabling engineers to predict and analyze the molding process with accuracy, these tools help identify potential design issues, optimize mold construction, and make informed decisions to enhance the quality of the final product. 

Ultimately, simulation software helps avoid design issues, reduce rework and scrap, save time and cost, and optimize the manufacturing process. In this article, we will explore everything you need to know about injection molding simulation software. 

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Injection Molding Simulation (Image Source: Pinterest)

What is Injection Molding Simulation Software?

Injection molding simulation is the process of using computer software to simulate the behavior of plastic material as it is injected into a mold cavity under specific process conditions. The simulation allows manufacturers to predict potential issues such as air traps, sink marks, and weld lines before creating physical molds, which can save time and money during the development process.

Simulation software works by using mathematical models to simulate the filling, packing, and cooling stages of the injection molding process. The software takes into account factors such as material properties, mold design, gate placement, and process parameters to create a virtual model of the molding process.

To perform a simulation, the software requires input data such as material properties, part geometry, and mold design. Material selection is an important factor, as different materials have different flow and cooling characteristics that affect the molding process. 

Process parameters such as injection speed, pressure, and temperature also have a significant impact on the molding process and should be considered when performing a simulation.

Overall, a basic understanding of input data, material selection, and process parameters is essential for successful plastic injection molding and simulation results. By accurately modeling the injection molding process, manufacturers can optimize the injection process and parameters and predict potential issues before creating physical molds, resulting in a more efficient and cost-effective manufacturing process.

Key Benefits of Using Simulation Software

The uses of simulation in business are varied and it is often utilized when conducting experiments on a real system is impossible or impractical, often because of cost or time. Below are some of its benefits: 

Risk-Free Environment

Simulation modeling provides a safe way to test and explore different “what-if” scenarios. The effect of changing staffing levels in a plant may be seen without putting production at risk. Make the right decision before making real-world changes.

Save Money and Time

Virtual experiments with simulation models are less expensive and take less time than experiments with real assets. Marketing campaigns can be tested without alerting the competition or unnecessarily spending money.


Simulation models can be animated in 2D/3D, allowing concepts and ideas to be more easily verified, communicated, and understood. Analysts and engineers gain trust in a model by seeing it in action and can clearly demonstrate findings to management.

Insight Into Dynamics

Unlike spreadsheet- or solver-based analytics, simulation modeling allows the observation of system behavior over time, at any level of detail. For example, checking warehouse storage space utilization on any given date.

Increased Accuracy

A simulation model can capture many more details than an analytical model, providing increased accuracy and more precise forecasting. Mining companies can significantly cut costs by optimizing asset usage and knowing their future equipment needs.

Handle Uncertainty

Uncertainty in operation times and outcome can be easily represented in simulation models, allowing risk quantification, and for more robust solutions to be found. In logistics, a realistic picture can be produced using simulation, including unpredictable data, such as shipment lead times.

There are various injection molding simulation softwares available in the market today. Some of them include Moldflow, Moldex3D, and Simpoe-Mold.

1. Moldflow

Moldflow is a simulation software that lets you troubleshoot problems with plastic injection and compression molding. Its advanced tools and a simplified user interface can help you address manufacturing challenges, such as part warpage, cooling channel efficiency, and cycle time reduction.

This simulation software allows you to connect product design teams, minimizing delays and rework costs through the following features: 

  • Autodesk Drive and Shared View enable content collaboration.
  • In-product Fusion 360 push for quick geometry changes.
  • Automation tools reduce setup and post-processing.

Moldflow Simulation software has the following benefits:

  • Minimizes solver hardware limitations by using Moldflow Insight.
  • Mesh and solves Insight jobs with local, remote, and secured cloud server options.
  • Runs multiple simulations concurrently with remote server and cloud solving.

2. Moldex3D

Moldex3D simulation software is the world leading CAE product for the plastic injection molding industry. With the best-in-class analysis technology, Moldex3D can help you carry out in-depth simulation of the widest range of injection molding processes and to optimize product designs and manufacturability. 

In addition, its high compatibility and adaptability provides you with an instant connection to mainstream CAD systems, generating a flexible simulation-driven design platform.

This leading true-3D molding simulation software can be applied in a wide range of plastic molding processes. You can use it to predict potential manufacturing defects, validate part/mold design, lower mold development costs, evaluate manufacturability, shorten time-to-market, and greatly increase the value of your business. 

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Designing using the Moldex3D simulation software (Image Source: Pinterest)

The main features of the Moldex3D software include:

  • One single platform to run all powerful Moldex3D simulations
  • Integrated workflow to ensure accurate meshing and modeling
  • Support multiple processes by applications

3. Simpoe-Mold

Simpoe-Mold is the stand-alone plastic injection simulation solution developed by SIMPOE. Thanks to this injection molding simulation software, you can now optimize the design and the tooling of their parts, and minimize your manufacturing costs, with  user-friendly, fast, complete and affordable tools, accessible to everyone.

Simpoe-Mold simulates the complete manufacturing process of plastic injected parts, from filling to warpage.  Whether you are a product designer, mold maker or part manufacturer, you can use Simpoe-Mold to identify manufacturing problems, study alternative solutions and directly assess the impact of such part modification. 

The Simpoe-Mold software suite includes the following packages:

  • SimpoeXplorer
  • Simpoe-Mold ENG
  • Simpoe-Mold MFG
  • Simpoe-Mold TOOL

Integrating Simulation Software into the Design Process

While simulation has been a part of mold making processes for quite some time, it has historically been used to drive troubleshooting and validation efforts, rather than design. The problem with limiting simulation to these areas is that it focuses on problem-fixing and problem-avoidance, rather than on trying to create truly optimized designs. 

Simulation software should predict and optimize how components will perform throughout each phase of the design and manufacture process. Digital prototyping aims to bring simulation into the process much earlier, so designs can be optimized using analysis results. 

Changes are much cheaper to make digitally on a computer than on a piece of steel that’s already been cut. However, the more complex the mold, the higher the cost – and the more important it is to use simulation.

By implementing simulation earlier in the development stages, mold designs can be analyzed and improved iteratively so potential problems are solved preemptively and products are optimized prior to starting production. This method has proven to be extremely effective because quality is now designed into the product and less testing is required in the later stages, which improves the overall efficiency of new product development.

Tips on Collaborating with Simulation Experts 

To ensure that you have optimal results with your injection molding simulation, you need to head to the following tips when collaborating with simulation experts. 

  1. Define your goals and scope
  2. Choose the right experts and platforms
  3. Establish clear roles and responsibilities
  4. Share data and information securely and effectively
  5. Review and validate the simulation and modeling outputs
  6. Apply and integrate the simulation and modeling outputs

Challenges and Considerations

Injection molding digital simulations are solving various challenges in employee upskilling, revolutionizing the learning and development landscape. Here are key challenges and how digital simulations address them:

Realistic Skill Development

Teaching practical skills can be challenging in traditional training environments. Digital injection molding simulations provide a lifelike setting for employees to practice and enhance their skills in a risk-free, controlled environment closely resembling their actual work conditions.

Engagement and Retention

Maintaining employee learning engagement and knowledge retention during training is often difficult. Digital injection molding simulations captivate learners through interactive and immersive experiences, making training enjoyable and improving retention rates.

Cost-efficient Training

Traditional training methods can be expensive, especially when replicating real-world production scenarios. However, modern injection molding simulations offer a cost-effective alternative by minimizing the need for physical resources, travel, and venue expenses.

Overcoming Geographical Constraints

For globally distributed teams, arranging in-person training can be challenging and costly. However, manufacturers can facilitate consistent training across geographical locations, ensuring all employees receive the same quality of upskilling experiences regardless of their location.‍

Promoting Continuous Learning

In a fast-paced manufacturing world, continuous learning is imperative. Simulation softwares facilitates ongoing training, allowing employees to revisit and reinforce their skills whenever needed, promoting a culture of continuous improvement and growth within the organization.

The Future of Injection Molding Simulation Software

Powered by artificial intelligence, machine learning and predictive analytics, the future of injection molding simulation looks bright. Let’s look at how the three technologies aim to improve simulation softwares in the parts manufacturing sector. 

AI and ML

AI/ML and simulation are distinct technologies that, when intersected, complement each other in some really powerful ways. First, there’s AI, which creates systems that mimic human behavior that are based on rules. 

On the other hand, machine learning (ML) is a subset of AI that enables computers to learn the rules automatically based on training data.  While they’re independent concepts, they’re continuously feeding each other. 

Simulations use AI and ML techniques to run models faster and easier. In turn, AI and ML use simulation to create synthetic data from a variety of industries and applications. 

Predictive Analytics

With predictive analytics, manufacturers can have simulation softwares that answers the ‘what-if?’ questions of the model and run scenarios. This allows for understanding of the future impact and consequence of each scenario, without incurring any risk or cost. 

This foresight provides powerful decision clarity across areas such as capital investments, resource planning and process design, or even service policies. Predictive simulation leads to smarter manufacturing decisions and drives higher return on investments.

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Simulation in Injection Molding (Image Source: Shutterstock


With the rapid progress in the plastic manufacturing industry, it is now possible to provide a full 3D simulation of the end product or component. Simulation works very well with thick and solid plastic parts like the dashboard of an automobile, the handles of a plastic chair, electrical connectors, etc.

The success of a molding process is not only dependent on the choice of the right software, but also on the boundary condition used in the simulation software. As competition intensifies, reliance on cutting edge injection molding simulation software is only going to increase. Every manufacturer that wants to stay competitive and innovative must thus adopt simulation software in their production process. 


Gary Liao

Gary Liao

Gary Liao is the Engineering Manager of TDL Company and has more than 20 years of mold design experience.

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