The link between the best design concept and a real-life product is the manufacturing process. Most manufacturing processes have a direct impact on the behaviour of the final product. Special purpose process simulations can help to improve the quality or performance of the final product on the one hand or to increase the efficiency of the process on the other hand.


Based on a CAD drawing either of the part or of the tool or mould, a numerical model of the manufacturing process can be built up, enabling to study the production process in a virtual environment. Most process simulation tools are highly specific for one production process such as injection moulding of plastics. This makes them accurate and very efficient at the same time.


At Code Product Solutions we are highly specialised in dealing with injection moulded plastics. Performing simulations of the mould filling process are one integral part of our integrated development approach for products made from plastics. Dealing with the manufacturing process in an early phase of the development phase allows to optimise both the process and the product to guarantee a certain quality level defined by the customer. This avoids cost-intense design changes later in the development phase when the design used to be frozen and the product is aimed to be produced.
Want to learn more about the software we use? Click here.

Virtual Tooling

Injection moulding simulations allow the assessment of several aspects related to the filling such as fill patterns, weld lines, air traps and other defects. By modelling details of the mould such as runner systems and cooling channels, the shrinkage and warpage behaviour of parts can be predicted. The knowledge of those insights allows our engineers to optimise either the part or the process in a way, the most optimal final product can be achieved when it comes to real-life production.

Composite Forming Analyses

With Hybrid Thermoplastic Composite parts, thermoplastic composites such as pre-consolidated laminates (so-called organosheets) or UD tape-based laminates are pressed in shape and backmoulded with thermoplastic resins. These forming or draping processes can be analysed by dedicated process simulation software. Our engineers apply those analyses to either optimise the forming process and tool design by predicting defects or other issues during processing. Or they predict the fibre orientations in the resulting laminate shape to take these into consideration within advanced structural simulations.

Fibre Orientation

Fibre filled injection moulded materials are often used in structural applications. With those materials, the fibres are oriented by the flow during the mould filling. These orientations impact the material behaviour significantly, since this turns anisotropic. At Code we have knowledge about the behaviour of those materials and how to handle these. Our engineers use process simulations to predict the locally varying fibre orientation impacting the performance of the final product. If necessary, we look into the smallest details to ensure the quality of the overall product.

✓  Improved quality of the final product
✓  Optimised production process
✓  Integrative product development
✓  Reduced waste during production
✓  Avoiding expensive tool revisions
✓  Reduced integral costs

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