Over 100 international experts from the injection moulding industry joined the International Injection Moulding Conference (IIMC) in Aachen. Code Product Solutions was glad to present to this audience about the advantages of Simulation-Driven Product Development. In this presentation, Dr. Jens van Haag showed in two automotive examples how a simulation-driven approach can improve developments, both in total product development and in the conceptual phase of the typical product development cycle.
Many thanks to Prof. Christian Hopmann and the whole team of the Institut for Kunststoffverarbeitung for the invitation to contribute to the IIMC. We are looking forward to the next IIMC, which will take place from 3rd to 4th of March, 2021.

The abstract of the presentation can be read below.

The practical implementation of a simulation-driven development approach of high-end products designed from plastics

The development of injection moulded products commonly requires a holistic approach. This involves taking into account several requirements throughout multiple development steps: integrating material, production and application specific design requirements. Successfully bringing these three aspects together requires considerable expertise. Code Product Solutions has been supporting their customers in the development of high-end products for over a decade. The company strongly believes in the benefits of this simulation-driven product development method and will show its practical advantages by means of the current presentation.

Nowadays, the benefits of using Computer Aided Engineering (CAE), meaning applying various kind of simulations in the development of products or applications, are well-known. However, questions remain at times, for instance about which kind of simulation leads to which level of accuracy and which approach would be best in specific stages. To allow insights into this topic, the presentation shows two practical examples which explain how simulation-driven process development improves the quality of complex injection moulded products and even allows for shortening development cycles.
The first example focuses on the total product development of a child car seat. This complex product, mainly made from plastic parts, undergoes severe crash load cases. It must fulfil certain requirements regarding the integrity of the structure but also in the transfer of loads to the infant it is carrying. This child car seat example shows how a simulation-driven development approach can aid in lowering the number of required hardware prototypes. This reduces time- and cost-intense iterations during the prototype homologation phase. Additionally, the question of when to apply which kind of structural simulation is discussed in this example.
The second example shows the concept development phase of an automotive sunroof frame. This case provides insights into how the benefits of simulation-driven product development can be generated in the initial concept phase. A great advantage is acquiring accurate feasibility checks early in the development process. This enables the possibility to evaluate business cases of multiple design options at a moment before profound investments have been done. In the given example, a fully plastic design and several hybrid thermoplastic composite designs are benchmarked against a costly steel-plastic hybrid version. The main goal of this assessment is to reduce the costs of the product. However, the potential to reach weight savings can be easily studied as a second focus within this method of virtual and predictive prototyping as well.

In short, a simulations driven-design approach in product development creates multiple opportunities and benefits, shown by the practical applications in this presentation. For more information on the topic and this engineering approach, get in touch with us!


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