Services

Effective strategies for plastic reduction

SmartMold Performs

1

Initial Part Design

Part design for plastic reduction through:
  • thickness reduction
  • volume reduction
2

Selection

Selection and characterization of the most effective functional coatings, taylored on the customer’s specific polymer.
3

Analysis

Analysis of plastic reduction potentials through accurate numerical simulations of the customer’s injection molding process.
4

New Part Design

Accurate structural analyses of the new part design to guarantee the required mechanical performance.
5

Functional Coatings

Functional coating of the customer’s mold through a partner coating supplier.

Thickness reduction

Benefits

A significant wall thickness reduction will bring several benefits:

  • Lower plastic consumption
  • Shorter cycle time
  • Lighter parts
  • Overall cost reduction

Thickness reduction

Benefits

A significant wall thickness reduction will bring several benefits:

  • Lower plastic consumption
  • Shorter cycle time
  • Lighter parts
  • Overall cost reduction

Thickness reduction

Limitations

Given a maximum available injection pressure in the original design, a significant wall thickness reduction causes higher pressure drop and short shots

Given a maximum available injection pressure in the original design, a significant wall thickness reduction causes higher pressure drop and short shots

Thickness reduction

Solution

Smart Mold develops and employs functional coatings that not only improve wear resistance and part ejection but facilitate cavity filling.

They produce a cooling delay during the filling phase, which significantly decrease the polymer viscosity and slightly increase the cycle time.

They enable wall thickness and cycle time reduction.

Volume reduction

Volume reduction is a very effective strategy but produces several weld lines that severely weaken the part structure.

Smart Mold selectively coats the mold cavity to create an unbalanced filling flow that shifts the weld line position and increase its strength.

Volume reduction

Volume reduction is a very effective strategy but produces several weld lines that severely weaken the part structure.

Smart Mold selectively coats the mold cavity to create an unbalanced filling flow that shifts the weld line position and increase its strength.

Easier processing of PCR plastics

Post-consumer recycled polypropylene is difficult to mold due to its high viscosity.

Smart Mold’s functional coatings facilitate cavity filling, enabling to mold higher fractions of high-viscosity PCR.

Easier processing of PCR plastics

Post-consumer recycled polypropylene is difficult to mold due to its high viscosity.

Smart Mold’s functional coatings facilitate cavity filling, enabling to mold higher fractions of high-viscosity PCR.

Smart Mold functional coatings

Working principle

Smart Mold functional coatings concentrate high thermal insulation power in a very thin layer, which delays the polymer cooling long enough to decrease its viscosity during the filling phase.

Increase weld line strength

Increase Weld Line Strength

Using the surface treatments as flow-leader, the flow inside the cavity is unbalanced. The so called in-flow effect (a pressure gradient) modified the weld line interface, increasing the shape, position and increasing their strength.

Facilitate cavity filling

Facilitate Cavity Filling

Reducing the injection pressure during the filling stage, the polymer better fill the cavity. A better filling results in a better part quality (the pressure is even distributed inside the cavity, reducing the shrinkage of the part).

Reduce Number of gates

Reduce Number of Gates

For complex part, characterized by high length-to-flow ratio, decreasing the injection pressure, results in a lower number of injection locations.