05 — Development
Moldflow simulation, rapid prototyping and mold optimization before serial production. We reduce technical risk and rework cost through successive digital and physical validations — from CAD file to injection T0.
Why we prototype
An injection mold is a major investment. Before building it, we validate geometry, material choice and process parameters through Moldflow numerical simulation and functional prototypes.
This way we eliminate 80% of technical risks — filling defects, warpage, sink marks — already in the design phase.
Our process
Design review, recommendations for moldability optimization (DFM): wall thicknesses, draft, radii.
Numerical simulation of the injection process: filling, cooling, warpage, optimized gate locations.
3D printing (SLA, FDM, SLS) for shape validation, assembly trials and ergonomic testing.
Construction of a 1-cavity mold for validating the real process and producing the first tens of parts.
Technologies used
3D simulation of the injection process: predicting filling, cooling, warpage, weld lines.
3D modeling, FEM analysis and direct collaboration with the customer's design team on native files.
SLA for fine details, FDM for functional parts, SLS for nylon prototypes.
4-axis milling for prototype metal parts and mold inserts with complex geometry.
Molds with aluminum or mild steel inserts for validation runs of 100 – 5,000 parts.
Initial trial, measurements, iterative mold adjustments until the target quality is confirmed.
Benefits
A day of simulation and a week of prototyping is worth months of modifications to a production mold that's already built.
| 3D printing technologies | SLA · FDM · SLS |
| 3D prototype tolerance | ±0.1 mm |
| Build volume | up to 350 × 350 × 400 mm |
| Simulation software | SolidWorks SIMPOE |
| CAD software | SolidWorks, CREO |
| Pilot mold | aluminum or mild steel, 1 cavity |
| 3D prototype lead time | 3 – 7 days |
| Pilot mold lead time | 3 – 6 weeks |
Continue exploring
We start with a free DFM analysis and concrete recommendations.