Injection molding simulation

Injection molding and transfer molding simulation

To uncover risks and optimization potential early on in product development, injection molding simulations of thermoplastic or thermoset plastic parts are used with the SIGMASOFT program. We continuously improve the accuracy of the injection molding simulation through comparison with experimental filling studies and the measurement of injection-molded parts with our 3D coordinate measurement technology.

Successful development of a plastic product and the associated injection molding tool with ever shorter development times requires a high degree of interdisciplinary competence, and extensive plastic expertise. Consequently, the injection molding simulations help the tool designer in the design phase to better understand the filling of the plastic part and to identify problems, such as air bubbles or knit lines in the part, in order to avoid complex retroactive tool adaptations.

Moreover, our material database of the most common plastic materials is a reliable basis for calculation of process-specific variables, such as fill times, tool thermal properties, holding pressure times, cooling times, and many other parameters. You can also characterize the plastics for special applications in our facilities and have this data flow directly into downstream injection molding or transfer molding simulations.   

Rheological configuration

  • Fill behavior
  • Balance and optimization of the gating system, as well as gate position, and gate area.
  • Formation and position of knit lines and air bubbles
  • Calculation of cooling time/crosslink time for thermosets
  • Calculation of fiber orientation 
  • Loading of inserts

Thermal configuration

  • Temperature development in the tool and part 
  • Optimization of tool thermal properties (e.g. cooling water/heating cartridges)
  • Influence of inserts 

Shrinkage and warpage*

  • Other processes:
  • Two-component injection molding
  • Use of the material orientation for FEM

*Currently not available for thermoset plastics 


Dr.-Ing. Tobias Grözinger
Phone: +49 711 685-83179