Beaumont Moldflow User Group 2025 – Agenda

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8:30-9:00am - Moldflow, What’s new and over the horizon?

This talk explores the latest advancements in Autodesk Moldflow, focusing on key features that enhance part quality and simulation efficiency. This includes key enhancements such as improved solver performance, default activation of the STAMP warpage model for 3D meshes, and new export capabilities like MP4 animation. These updates aim to streamline workflows and improve result accuracy.

9:00-9:30am - Simplifying Everyday Moldflow Tasks with Artificial Intelligence

While Autodesk Moldflow is the industry standard for injection molding simulation, it currently does not include built-in AI functionality. This presents a powerful opportunity for users to harness external AI tools and techniques to streamline everyday Moldflow tasks. This presentation will demonstrate how the integration of AI-driven insights can complement traditional simulation processes, allowing users to significantly reduce repetitive work, improve overall simulation accuracy, and enable faster, more informed decisions. Attendees will leave with practical strategies for making their Moldflow practice more intelligent and efficient, moving beyond the limitations of the software's native capabilities.

9:30-10:00am - Assessing the Integrity of .udb files

Obtaining a .udb file for your material can be challenging, but an even greater challenge is determining its suitability for your specific application. This presentation outlines a comprehensive approach to evaluating a .udb file, moving beyond simple acquisition to a deeper understanding of its integrity and potential impact on simulation results.

10:30-11:00am - Pressure Drop: Decoding the Secrets

Pressure drop is a critical aspect of injection molding, yet its interpretation can be complex and multifaceted. The methods available for measuring this pressure—from in-mold cavity pressure sensors to machine-side pressure readings—can provide different insights. A major challenge lies in effectively comparing these real-world measurements with data from simulation software. Factors like the formation of the frozen layer against the mold walls, the speed of the fill phase, and the geometry of the runner system all play a significant role in how pressure develops. This presentation will use a variety of practical examples to explore and demystify the most effective methods for analyzing and understanding pressure development in injection molded systems.

11:00-11:30am - Modeling Techniques for Overmolded Inserts

Overmolded inserts are commonly used in injection molding, but they can introduce challenges such as increased heat load, warpage, and other production issues. Autodesk Moldflow simulation can predict these problems before production, but only if the correct modeling techniques are used. This presentation will focus on the three primary mesh types in Moldflow—Midplane, Dual Domain, and 3D—and how the selection of the appropriate mesh type is crucial for ensuring simulation accuracy. By understanding how to properly model these inserts, engineers can achieve a more streamlined simulation process and generate reliable results, saving time and resources.

11:30-12:00pm - Techniques for Optimizing Small or Micromolded Parts Using Autodesk Moldflow

Autodesk Moldflow is a powerful tool for optimizing plastic component manufacturing. However, its default settings and workflows might not meet the unique demands posed by the latest generation of small and complex injection molded parts produced by processes like micromolding. This advanced process creates ultra-small, high-precision thermoplastic parts, achieving tolerances in microns and handling shot weights as minimal as 0.1 grams.Dive deep with us to explore how Autodesk Moldflow breaks traditional boundaries, enhancing the precision and efficiency of micromolding. Learn how integrating advanced simulation techniques, comprehensive material data, and innovative capabilities can push the limits of what’s possible in this field. Join us and stay ahead in the future of injection molding.

1:00-1:30pm - Procuring Autodesk Moldflow through Beaumont – FAQs & General Overview

In June 2024 Autodesk launched their “New Buying Experience” which aimed to give end-customers more oversight and security over the procurement of their Autodesk software. Since this new software procurement platform was launched, we’ve identified several questions we have been receiving on a regular basis. As a Verified Autodesk Reseller, Beaumont Technologies would like to review these frequently asked questions and provide our answers. The goal of this presentation is to ensure that our Moldflow users have all the answers they need to confidently make decisions regarding their software procurement. At the end of this presentation, we will open the floor to our users for any additional questions.

1:30-2:00pm - Pressure Drop Studies…Are Air Shot Pressures Accurate?

Most processors these days are taught to do a Pressure Loss Study as part of their Scientific Molding practices. The main purposes for the study include: 1. determine which sections of the material flow path are consuming the greatest amount of pressure, 2. determine how much pressure is required to fill the mold by subtracting the air shot pressure from the machine’s pressure at transfer, and 3. determine the accuracy of mold filling simulation pressure predictions. Previous research will be summarized that shows errors with the practice of doing pressure loss studies at various steps through the mold. This will build into recent research that now questions the accuracy of the air shot pressure, in particular for materials whose viscosity is pressure sensitive. Studies will be shown that compare the pressure loss both during an air shot and during the molding cycle by incorporating a pressure sensor in the machine nozzle tip. The results will also be compared to Autodesk Moldflow simulation predictions, and how differences in the pressures could be misinterpreted. The research could ultimately call into question the entire practice of performing Pressure Loss Studies for some materials.

1:30-2:00pm - Pressure Drop Studies…Are Air Shot Pressures Accurate?

Most processors these days are taught to do a Pressure Loss Study as part of their Scientific Molding practices. The main purposes for the study include: 1. determine which sections of the material flow path are consuming the greatest amount of pressure, 2. determine how much pressure is required to fill the mold by subtracting the air shot pressure from the machine’s pressure at transfer, and 3. determine the accuracy of mold filling simulation pressure predictions. Previous research will be summarized that shows errors with the practice of doing pressure loss studies at various steps through the mold. This will build into recent research that now questions the accuracy of the air shot pressure, in particular for materials whose viscosity is pressure sensitive. Studies will be shown that compare the pressure loss both during an air shot and during the molding cycle by incorporating a pressure sensor in the machine nozzle tip. The results will also be compared to Autodesk Moldflow simulation predictions, and how differences in the pressures could be misinterpreted. The research could ultimately call into question the entire practice of performing Pressure Loss Studies for some materials.

2:00-2:30pm - Advancing Warpage Prediction with STAMP: Ongoing Research on Validating Digital Twin Accuracy

This presentation provides an update on the results of an ongoing research project focused on validating the STAMP warpage model through experimental molding trials. Several polyolefin resins, with varying additive and filler packages were processed under different thicknesses, gate locations, and process parameters to study the shrinkage behavior in both flow and crossflow directions, as well as part deflection. Molded parts were 3D scanned and compared against simulation predictions to assess the correlation with the uncorrected residual stress model and STAMP. This research supports efforts to improve “digital twin” accuracy, providing greater confidence in the software when validating new tooling and predicting part warpage.

3:00-3:30pm - Moldflow Meshing Challenge: Results and Takeaways

Earlier this year, Autodesk employees and Moldflow customers participated in a "Meshing Challenge" where the goal was to compare the different meshing approaches from our Moldflow user base. The participants were provided the same CAD model and basic instructions for the exercise. After the entries were submitted, we ran each study file and collected key results for comparison. This presentation summarizes the results and highlights key takeaways from this study.

3:30-4:00pm - Moldflow Research & Development Updates

Autodesk Moldflow is continuously evolving, and recent R&D efforts have focused on enhancing simulation accuracy, speed and user experience. This presentation will provide a comprehensive overview of how these R&D updates empower engineers to achieve more accurate and efficient injection molding simulations.