ADD ON Modules

Moldex3D SYNC is a user-friendly, multifunctional interface fully embedded into CAD software, enabling a continuous workflow from plastic product design to simulation. By integrating Moldex3D directly into the CAD software environment, designers can create and modify models within their familiar CAD interface, set up process conditions, and directly run professional injection molding analyses. Moldex3D SYNC is currently available for PTC® Creo®, NX, and SOLIDWORKS® CAD software.

Moldex3D CADdoctor is an interactive geometry repair tool that supports data import from multiple CAD formats. It provides geometry simplification and verification, model quality inspection for CAE analysis, as well as automatic detection and correction of defective geometries. Moldex3D CADdoctor enhances mesh quality to improve the accuracy of simulation results.
Moldex3D CADdoctor was developed through a partnership between CoreTech System (Moldex3D) and Elysium.

Fiber-reinforced plastics have become a key structural material in various industries, such as automotive, electrical, and construction, due to their superior mechanical properties and thermal resistance. The quality of the final product can be significantly improved by optimizing the length, orientation, and concentration of fibers. Fiber orientation is influenced by the melt flow during the filling process, leading to anisotropic material properties. Fiber breakage is often caused by improper part design, gating system layout, and injection molding conditions. The Fiber module effectively identifies and addresses both the issues of fiber orientation and fiber breakage in a clear and comprehensible manner.
Anisotropic fiber orientation is crucial in determining the non-homogeneous shrinkage and stiffness of molded parts. The Fiber module results provide a fundamental step towards achieving high-quality plastic products.

The Stress add-on provides a detailed analysis of the stress distribution in parts and inserts. Users can define boundary conditions, such as stress or applied force, to assess the structural quality of plastic components and predict potential damage or deformation.

The FEA Interface is a series of modules that integrate Moldex3D simulation results with structural analysis software such as ABAQUS, ANSYS, LS-DYNA, Marc, Nastran, and Radioss. The FEA Interface enables the export of analysis results, including fiber orientation, pressure distribution, temperature, weld lines, and residual stresses, for further structural evaluation in these specialized platforms. Moldex3D FEA also supports the mapping of fiber orientation data from a 3D mesh onto a 2D shell mesh.

Digimat RP assists users to accurately design fiber-reinforced plastic components. Users are able to quickly obtain precise material models for reinforced plastics and apply them to finite element models for structural analysis using a simplified workflow. Reinforced plastics are widely used across numerous industries as a primary material to enhance stiffness with minimal weight increase. One of the major challenges for developers is the reliable prediction of structural performance in components made of composite materials, as the fiber orientation induced during the molding process significantly affects mechanical properties.
Moldex3D Digimat-RP offers a simple, efficient, and highly accurate solution for reinforced plastics, enabling users to properly design fiber-reinforced plastic parts. Users can quickly generate accurate material models and incorporate them into finite element simulations via an optimized and streamlined workflow.                               

MMI is a module that enables users to obtain extended material properties for nonlinear multiscale material modeling by integrating software such as Digimat or Converse prior to data input into structural FEA software. This data conversion significantly enriches the material information with respect to:

AHR is a module used for optimizing the design of a mold’s hot runner system. It allows the modeling of the complete hot runner assembly, including all of its details (e.g. channel geometry, nozzles, torpedoes, valve pins and their movements, heating elements, and sensors). It visualizes the viscoelastic behavior of the melt during filling and the temperature distribution within the hot runner system and mold. Users can evaluate the heating efficiency and uniformity to optimize the hot runner design.

This module analyzes issues in transparent optical plastic components caused by photoelasticity, which is caused by internal stresses induced by melt flow and non-uniform solidification. The Moldex3D Optics module enables investigation into the root causes of birefringence and light retardation, providing graphical visualization of isoclinics and isochromatics, and supporting the optimization of their location and intensity within the product. It is also possible to export the deformed shape and refractive index distribution to specialized software such as CODE V for further verification and design optimization.

The module takes into account the variability of melt viscosity and elasticity under different thermal conditions, and the resulting macromolecular orientation, which results in residual stress in the finished product. Residual stress (internal strain) significantly impacts mold deformation, mechanical strength, and optical properties.
Moldex3D Viscoelasticity assists users in visualizing polymer changes over time within the cavity. Additionally, it can be integrated with the Warp or Optics modules to provide advanced analyses.

Moldex3D Expert assists in optimizing process conditions, component, and mold design by using the Design of Experiments (DOE) method. Based on the selected parameters/factors, the Expert module automatically generates and counts analysis variants and provides their graphical evaluations.

This module simulates the compression molding process, in which a molding polymer—referred to as a charge or compound—is compressed into a preheated mold cavity under pressure until the material cures. Moldex3D assists users in identifying potential defects caused by heat and pressure distribution, selecting appropriate materials, and optimizing process conditions. Moldex3D supports a wide range of fiber-reinforced materials, including continuous fiber thermoplastics such as GMT, LFT-G, and LFT-D. It also supports thermosets such as SMC and BMC.

Injection Compression Molding (ICM) is a manufacturing process that combines injection molding and compression molding techniques. The mold is not fully closed during the filling phase. After the cavity is partially filled with molten material, the mold is completely closed. The injection process is thus completed by a compression step (closing of the mold).
ICM combines the advantages of conventional injection molding with those of compression molding. It is particularly used for producing ultra-thin-walled parts, components with low internal stress, or for accurately transferring fine surface textures from the mold to the product. The ICM module helps optimize this complex process.

PIM visualizes the molding process of a polymer binder highly filled with metal or ceramic powder. Users can observe melt behavior, the influence of shear rate, weld line formation, volumetric shrinkage, and optimize component design, mold design, and processing conditions.
Powder Injection Molding (PIM) technology originated in 1973. In this process, ceramic or fine metal powder is mixed with a measured amount of binder to create a feedstock. The injection process forms a so-called “green part,” which then undergoes debinding and sintering processes. The result is a metal or ceramic component with a complex geometry, high surface quality, and precise dimensions.

GAIM visualizes the melt behavior after injecting gas into the mold cavity through a specialized nozzle. Users can predict common GAIM-related issues such as gas channel branching, wall blow-through, or corner effects.
Gas-Assisted Injection Molding (GAIM) provides mechanical stiffness and dimensional stability for thick-walled parts, eliminates warpage and surface sink marks, and reduces residual stress. In GAIM systems, plastic parts are molded with lower injection pressure and less material, leading to savings in both energy and weight.
The major challenge in GAIM is managing gas flow due to the differing flow characteristics and resistance between gas and molten plastic. Moldex3D GAIM provides tools for simulating gas injection into the cavity, either through melt inlets or specified gas entry points. The 3D model enables users to visualize gas penetration into the mold cavity and further optimize part/mold design and process settings.

This technology visualizes the dynamics of the injection molding process for hollow parts using water assistance. By visualizing the behavior of fluid penetration into the mold cavity, users can define the overflow cavity and optimize process conditions.
Water-Assisted Injection Molding (WAIM) is a specialized injection molding technique based on similar principles as Gas-Assisted Injection Molding (GAIM). However, water is used instead of an inert gas. Additionally, water serves as a cost-effective packing medium with high thermal capacity and thermal conductivity, significantly reducing cycle time.

Co-injection molding visualizes the sequential injection process of two plastic materials into a sandwich structure consisting of a skin layer and a core. The user is able to optimize the intentional core breakthrough on the surface of the part.
CoIM produces a plastic part with a layered skin-core structure using a simultaneous injection process. First, the skin material is injected into the mold, followed by the core material, and finally, the skin material is injected again to encapsulate the core. Thus, the process enables to produce a part with the desired aesthetic properties of the outer skin material. Due to this layered structure, co-injection molding is extensively used to incorporate regrind or recycled materials as the core (second shot), offering environmental and cost-saving benefits. Conversely, this process can also enhance mechanical strength by using high-strength polymers in the core.

Bi-injection molding visualizes the process of independently injecting two materials into a single mold cavity. Users can define material types, set independent filling and packing parameters for each material, and monitor the flow behavior from two melt entrances.
BiIM is a variant of multi-component injection molding. It is commonly used for producing dual-color products such as automotive lights, mobile phone housings, toothbrushes, etc. In this process, two plastic materials are injected into one mold cavity through two separate gates. The plastic flows meet inside the cavity, resulting in various flow front configurations. The position of the interface line between the two materials can be controlled by regulating the flow rate. Therefore, the use of Moldex3D is crucial for verifying and optimizing component/mold designs, processing parameters, and more.

This simulation captures the formation and growth of microcells during melt injection into the mold cavity. Moldex3D Foam Injection Molding assists users in determining optimal processing parameters to eliminate potential defects and deformation issues.
Foam injection molding technologies, such as MuCell® and Chemical Blowing Agent (CBA) processes, enable high-volume production of complex parts with excellent dimensional stability. In addition, the above-described methods are widely used across the automotive industry, electronic/electrical products, construction, outdoor goods, and various other applications.
In the MuCell® process, a supercritical fluid (SCF)—typically nitrogen (N₂) or carbon dioxide (CO₂)—is mixed with the polymer melt to form a single-phase polymer-gas solution. This solution is subsequently injected into the mold cavity, where microcells form within the molded part. In the CBA process, chemical blowing agents are blended with plastic pellets as colorants or additives. A chemical reaction occurs inside the injection barrel, and gas is dissolved into the melt. During the filling stage, pressure is released and gas bubbles begin to expand, creating a cellular structure in the final part.
The advantages of this technology include reduced injection pressures, lower processing temperatures, shorter cycle times, energy savings, and material efficiency. However, the introduction of supercritical fluids adds complexity to melt behavior, material morphology, and surface quality, which can hinder broader adoption and development of the process.

The RTM process utilizes non-isothermal 3D analysis to visualize flow behavior across various applications. Users can verify and evaluate the effects of different fabric types and fiber orientations.
Resin Transfer Molding (RTM) is one of the primary Liquid Composite Molding (LCM) processes. It is widely used due to its ability to reduce production time while achieving high mechanical strength of the final product.

Chemical Foaming Molding (CFM) is an injection molding process where the cavity is entirely filled with foam generated through chemical reactions.
CFM involves the full filling of the mold cavity with polymer foam created through chemical reactions. The molding of polyurethane foam is the most common form of chemical foaming. Based on their mechanical properties, foam products are typically categorized into two types: rigid and flexible foams. Rigid foam does not return to its original shape after compression, whereas flexible foam can recover its shape after deformation.