Frequently Asked Questions

How can Moldflow analysis help your Product Development?

Moldflow analysisMoldflow software allows the flow of plastic inside a mould tool during the injection moulding process to be analysed. The 3D CAD data generated during the design process can be used directly to determine the manufacturability of the part.

Material, tool and moulding parameters are assigned to the geometry and the analysis run. The results generated are numerous and detailed and include full time pressure, temperature, weld lines, areas of poor flow and sink marks. More complex analysis can show warpage, areas of distortion, fibre flow and shrinkage. 

When should we use moldflow analysis?

A mould with a more complex shape will likely benefit from moldflow analysis because the flow is less predictable than with a simpler shape. The current trend is to make products lighter & thinner to save material cost but this makes moulding quality parts more difficult. The ability to optimise the gate location can prove essential for some parts with more complicated geometries.Moldflow analysis

Changes to the part design and also the tool design can be investigated and confirmed based on the moldflow output and potential quality issues in the part such as deep under cuts or inadequate draft angles can then be altered immediately to address these issues with little time and cost.

The benefits of using moldflow analysis 

The advantages of moldflow are many, and the ability to see how a manufacturing process will work before financial outlay has been committed to tooling is priceless. 

At Plunkett Associates we regularly use moldflow analysis so that new part designs can be analysed immediately for manufacturability. This includes not just the ability to mould a part, but also the quality of the resulting part, both physically and aesthetically. Moldflow

In the past there was a risk that flaws in part designs would not be noticed until a mould tool was made. Creating a virtual version through moldflow analysis, means multiple trials can be avoided and time and money saved, as changes in part and mould design at this stage would be far more expensive.

If you think analysis would help your product development, give us a call, we will be glad to assist.

  • “Plunkett Associates have excellent breadth of experience, work with high quality partners and have a flexibility that we have found enables challenges to be met successfully, cost effectively and in a timely manner.”
    Nick Skaer, CEO, Orthox Ltd
  • Plunkett associates always find a solution. Whatever we need to prototype, they have a great grasp on the technologies available, costs and lead-times so we get the right solution tailored to the project needs. Have always delivered and never let us down.
    Naim Audio
  • “I can’t recommend Tim and his team highly enough. We ended up with a design which can be produced and assembled quickly, efficiently and reliably, in volumes that make sense”
    Simon Leggett, Director, Olivewood Technology
  • "Tim's experience, expertise and supplier base have been fundamental to us getting this project off the ground."
    Sam Pearce, Jelly Products Ltd
  • “We were really surprised at how quickly they turned round such a high quality prototype and the parts certainly proved their worth. They were of high enough quality to provide a fantastic visual representation and to undergo rigorous testing."
    Stuart Wilson, Design Director, TRT Lighting
  • “Accuracy, finish and delivery all first class.”
    Andrew Peters, JMDA Ltd
  • “We use Plunkett Associates because we want someone we can trust, that knows what they’re talking about, has all the contacts, will provide reliable advice and feedback and will get the right result for us.”
    Jim Copestick. Design Manager, Thorlux Lighting
  • “We always know exactly what we’re getting and we know we won’t be let down on quality, price or lead times.”
    Mark Williams, Research and Development Director, Johnson Safety Products
  • “Plunkett Associates truly offer a complete turnkey solution with Speed, Effectiveness and Precision.”
    David Harden, Director, Enica Ltd
  • “Kirintec were thrilled with Plunketts. They made a complex process simple and we were just amazed at the lead times achieved. Plus, every single deadline was met without any drama.”
    Penny While, Marketing Director, Kirintec
  • “Thanks to Plunkett Associates flexible, bespoke and cost effective service I was able to produce the objects that I had originally had in mind.”
    Simon Ryder, Artist
  • To create such a consistent quality finish in chrome was an amazing achievement and the prototypes really gave our stand the wow factor.
    James Clark, Group Commercial Director, The Airdri Group
  • Interestingly, people who look at it in its own right with little knowledge of what it does, just like it! It’s tactile and it looks good…
    Tim Collings, Operations Director, Troika Systems Ltd
  • "With their simple to understand language, willingness to go the extra mile and approachability, Plunkett Associates were a great partner for our company. We couldn’t be happier with the results of our project. (A working prototype that they got right first time, by the way). Thank you!"
    Carolina Ballon-Forrester, Director, Kittyrama Ltd
  • Plunkett Associates worked on the design and production of titanium frames for an artificial heart valve where precision and consistency was paramount. Communications were efficient and productive with concepts readily incorporated into the final design, and suggestions for improvements all highly appropriate. The quality of the end product was ideal and I have no doubt that I will use the advice and expertise of Plunkett Associates again.
    David Wheatley, Wheatley Research Ltd
  • “Thanks for the present that arrived this morning, as promised. Parts look first class, as always.”
    Jon Todd, Design Manager, PHS Group
  • “Plunkett Associates have a fantastic supply chain, work with all sorts of production processes and will always do their utmost to solve a problem.”
    Naim Audio
  • “ Plunketts developed a solution that met our precision requirements at a cost significantly lower than alternative manufacturing approaches we had investigated”
    Nick Skaer, CEO, Orthox Ltd
  • “Doing business with you has been an absolute pleasure. You have made my goals a reality. You have been patient, helpful and above all, responsive. Best service that I have experienced in ages. I consider Plunkett Associates to be an integral part of my business plan moving forward.”
    Jet Cooper, Sculptor

Read more expert articles in our FAQ section where we discuss topics on materials, methods and products.

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  • “Plunkett Associates have excellent breadth of experience, work with high quality partners and have a flexibility that we have found enables challenges to be met successfully, cost effectively and in a timely manner.”
    Nick Skaer, CEO, Orthox Ltd
    Nick Skaer, CEO, Orthox Ltd
  • Plunkett associates always find a solution. Whatever we need to prototype, they have a great grasp on the technologies available, costs and lead-times so we get the right solution tailored to the project needs. Have always delivered and never let us down.
    Naim Audio
    Naim Audio
  • “I can’t recommend Tim and his team highly enough. We ended up with a design which can be produced and assembled quickly, efficiently and reliably, in volumes that make sense”
    Simon Leggett, Director, Olivewood Technology
    Simon Leggett, Director,  Olivewood Technology
  • "Tim's experience, expertise and supplier base have been fundamental to us getting this project off the ground."
    Sam Pearce, Jelly Products Ltd
    Sam Pearce, Jelly Products Ltd
  • “We were really surprised at how quickly they turned round such a high quality prototype and the parts certainly proved their worth. They were of high enough quality to provide a fantastic visual representation and to undergo rigorous testing."
    Stuart Wilson, Design Director, TRT Lighting
    Stuart Wilson, Design Director, TRT Lighting
  • “Accuracy, finish and delivery all first class.”
    Andrew Peters, JMDA Ltd
    Andrew Peters, JMDA Ltd
  • “We use Plunkett Associates because we want someone we can trust, that knows what they’re talking about, has all the contacts, will provide reliable advice and feedback and will get the right result for us.”
    Jim Copestick. Design Manager, Thorlux Lighting
    Jim Copestick. Design Manager, Thorlux Lighting
  • “We always know exactly what we’re getting and we know we won’t be let down on quality, price or lead times.”
    Mark Williams, Research and Development Director, Johnson Safety Products
    Mark Williams, Research and Development Director, Johnson Safety Products
  • “Plunkett Associates truly offer a complete turnkey solution with Speed, Effectiveness and Precision.”
    David Harden, Director, Enica Ltd
    David Harden, Director, Enica Ltd
  • “Kirintec were thrilled with Plunketts. They made a complex process simple and we were just amazed at the lead times achieved. Plus, every single deadline was met without any drama.”
    Penny While, Marketing Director, Kirintec
    Penny While, Marketing Director, Kirintec
  • “Thanks to Plunkett Associates flexible, bespoke and cost effective service I was able to produce the objects that I had originally had in mind.”
    Simon Ryder, Artist
    Simon Ryder, Artist
  • To create such a consistent quality finish in chrome was an amazing achievement and the prototypes really gave our stand the wow factor.
    James Clark, Group Commercial Director, The Airdri Group
    James Clark, Group Commercial Director, The Airdri Group
  • Interestingly, people who look at it in its own right with little knowledge of what it does, just like it! It’s tactile and it looks good…
    Tim Collings, Operations Director, Troika Systems Ltd
    Tim Collings, Operations Director, Troika Systems Ltd
  • "With their simple to understand language, willingness to go the extra mile and approachability, Plunkett Associates were a great partner for our company. We couldn’t be happier with the results of our project. (A working prototype that they got right first time, by the way). Thank you!"
    Carolina Ballon-Forrester, Director, Kittyrama Ltd
    Carolina Ballon-Forrester, Director, Kittyrama Ltd
  • Plunkett Associates worked on the design and production of titanium frames for an artificial heart valve where precision and consistency was paramount. Communications were efficient and productive with concepts readily incorporated into the final design, and suggestions for improvements all highly appropriate. The quality of the end product was ideal and I have no doubt that I will use the advice and expertise of Plunkett Associates again.
    David Wheatley, Wheatley Research Ltd
    David Wheatley, Wheatley Research Ltd
  • “Thanks for the present that arrived this morning, as promised. Parts look first class, as always.”
    Jon Todd, Design Manager, PHS Group
    Jon Todd, Design Manager, PHS Group
  • “Plunkett Associates have a fantastic supply chain, work with all sorts of production processes and will always do their utmost to solve a problem.”
    Naim Audio
    Naim Audio
  • “ Plunketts developed a solution that met our precision requirements at a cost significantly lower than alternative manufacturing approaches we had investigated”
    Nick Skaer, CEO, Orthox Ltd
    Nick Skaer, CEO, Orthox Ltd
  • “Doing business with you has been an absolute pleasure. You have made my goals a reality. You have been patient, helpful and above all, responsive. Best service that I have experienced in ages. I consider Plunkett Associates to be an integral part of my business plan moving forward.”
    Jet Cooper, Sculptor
    Jet Cooper, Sculptor