Polyram Group

Polyram Launches In-House CAE Capabilities

Polyram Launches In-House CAE Capabilities

Computer Aided Engineering (CAE) has been a hot topic for some time, led by the automotive industry.

As challenges for cost and material saving combined with more complex design and engineering requirements are faced, the automotive industry has had to adopt innovative tools to improve planning of design and manufacturing of parts.

Correct planning with CAE can help gain short time to market and considerable savings every step of the way.

From reducing mold design changes, to ensuring flow of production with less downtime and creating robust, reliable and high quality parts while reducing the quantity of faults.

Other industries have followed and have adopted digital software for 3D modeling and tooling needs.

Polyram now offers advanced CAE capabilities in-house, with Moldex 3D and Cimatron software. As part of our high end service to clients, Polyram specialists accompany and support you throughout the concepting, planning and manufacturing process.

 

 

Why CAE?

 

Computer Aided Engineering (CAE) at Polyram allows us to be much more than a compounder to our clients.

We collaborate from day one to help in the planning for a specific, customized part - from selecting the right Polyram compound in accordance with weight and other characteristics required, to assisting in design validation and mold design, to support during injection on site.

Our experts are ever present to guide you every step of the way, to ensure smooth planning and production with significant cost savings, getting the mold right, and ensuring the Correct compound selection to get the part just right.

By using CAE software such as Moldex 3D and Cimatron, we can predict compound behavior and detect weakness points.

We can optimize injection and molding parameters to ensure highest quality for the final product.

Designing a new part with CAE, allows for important data to be available early in the planning process. Thus costly changes to the mold and various faults during production can be avoided, with money saved.

The automotive industry has seen a shift in the role of the compounder in recent years.

Compounders are expected to provide a complete engineering service suite that includes CAE.

The compounder is expected to run flow-analysis for various materials and mold designs, perfecting the mold design and matching the best compound to achieve customized part specifications.

The main challenges are:

  • Replacing metal parts with plastic compounds – In these cases, it is important to perform a feasibility study in order to make sure the switch is possible in terms of mechanical and rheological behavior
  • Designing parts that are even more lightweight – by reducing material thickness (In these cases, getting the molding process and material flow in the mold just right is VERY important to avoid faulty parts and breakages.)
  • Designing parts that are even more lightweight – by changing materials (In these cases matching a new compound and testing various injection options is essential to optimizing the design and achieving the required spec.)
  • Detecting weak points – to avoid faulty products, waste of resources, and breaking during use.
  • Product life cycle support - from development to manufacturing to actual use.
  • Feasibility check and validating new designs - saving considerable costs with early flaw detection and correction at the prototype mold stage.

 

For the last 6 months, Polyram has been closely collaborating with Moldex 3D in order to deeply learn their software and to integrate it flawlessly into the Polyram R&D and the manufacturing process.

We have worked on flow analysis and have conducted simulations for major automotive manufacturers and Tier 1 OEMs successfully.

We work with both the end user to help perfect the final product with Moldex 3D, and with the mold manufacturer, using Cimatron, to ensure the mold has been properly planned to fit with our compound.

Following a simulation, flow-analysis reports are created for any changes to the mold, for advanced optimization.

We look for material thickness and flow directions to ensure a Robust and reliable part is eventually manufactured.

 

Full support - From concept to manufacturing

We strive to assist our clients in the earliest stages of development, making sure the entire process is more effective and less costly.

By matching the right compound to specific part requirements and testing various mold designs using the CAE simulations, we help our clients perfect their design before even one cent has been spent on mold manufacturing or the part’s production. 

The more we know about the characteristics a new part requires, the more exact and realistic the simulations that can be performed. Polyram values its role as development consultant greatly, as we believe this service is the best way to help our clients excel and grow their business.

Ployram stands fully behind its compounds. To top off all the planning, simulation and testing phases, we also support our clients at the production site to ensure all goes smoothly.

 

What’s next?

 

To continue the highest level of support for our clients, we intent to register Polyram trademarked grades into the international Moldex 3D material catalog.

Thus our compounds will be available for selection and use by any engineer who has access to this data base.

Engineers in various industries will be then able to design parts based on our compounds. Registration to the catalog involves strict laboratory testing by Moldex 3D, to ensure enhanced entries, which contain detailed material properties.

We expect to enter our leading compounds into the catalog by the end of the year.

 

For further information about our in house CAE simulation capabilities, contact Jacob at jacob@polyram-group.com

 

 

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