Cross-Study of Techniques for the Analysis of Deformations Generated in the Injection Molding Process

Abstract

Injection molding is a plastic material processing technique used in the polymer industry. Because it is a complex process that requires injection cycles to achieve the desired aesthetic quality in the molded parts, it is essential to evaluate and configure all process parameters to predict and reduce defects, thereby decreasing the processing time and energy consumption. This study presents the results of tests performed on molded HDPE parts, including modeling and simulation using ANSYS® (2025 R1), a design of experiments (DOE), and 3D scanning of the molded parts. The study compares the behavior of defects (warpages and sink-marks) in molded parts using 3D scanning with the results obtained from coupled thermal-structural field finite element simulations. These simulations were performed using software to assess the residual thermal stress of the ejection phase. The results visually display information that helps designers and engineers in the polymer processing sector evaluate molding-process failures using different software.