Mold Flow Analysis Guide
Fill Time Result
The Fill Time Result shows the position of the flow front at regular intervals as the mold cavity fills.
A part is considered to have a good Fill
Things to look for:*
Time Result when the flow pattern is
balanced. 1 Short Shot
A part is short shot when the flow of plastic does not completely fill the
mold cavity, thereby resulting in an incomplete part. This can be caused by
In the following diagrams, contour colors flow restrictions, long/complex flow paths, poor venting, low melt and/or
represent the flow pattern of plastic into the mold temps, and insufficient material, for example.
part. Remedies may include: eliminating Air Traps, changing part geometry to
balance flow paths, choosing a less viscous material (higher melt flow
• All regions with the same color are filled rate), and increasing the maximum injection pressure for the part.
simultaneously
Hesitation
• The result is dark blue at the start of the Hesitation occurs when the flow of plastic stops or slows down resulting in
injection. The last areas to fill are red asymmetrical and unpredictable flow patterns. When given the option, the
flow is likely to fill thick areas of a cavity first - which can result in uneven
• If the part is a short shot, the section cooling time and part defects.
that did not fill will not have color (See Remedies may include: moving the polymer injection so that the bulk of
Things to look for.) the cavity fills before the melt reaches the thin area and/or to a place that
will apply pressure where the hesitation occurred, increasing wall thickness,
Diagram 1 using a less viscous material, injecting more quickly, and increasing the
melt temp.
Overpacking
Overpacking is the result of one flow path finishing before others. Most
likely to occur in sections with the shortest fill time, overpacking can cause
high part weight, warp, and non-uniform density distribution. To avoid, try
Diagram 2 using a machine with higher clamp force, check venting, and ensure mold
plates fit correctly.
Weld Lines
Weld lines (knit lines/meld lines) are molding defects that occur when two
flow fronts meet without the ability to "weld". They typically occur around
Image courtesy of Autodesk holes or obstructions which can result in locally weak areas in the molded
part. Avoid weld lines in areas which need strength, or need to appear
Using this result2 smooth.
Remedies may include: Changing the polymer injection location or altering
Diagram 1
wall thicknesses to set up a different fill time.
• All flow paths finish at the same time and
reach the edges of the model Air Traps
simultaneously An Air Trap is a bubble of air that gets trapped when plastic flow fronts
coincide. Air traps can cause structural and visual defects in a plastic part
• The contours are evenly spaced and such as blemishes on the surface and incomplete filling. One way to reduce
indicate the speed at which the polymer the risk of air traps is to modify the filling pattern by reducing the injection
is flowing. Widely-spaced contours speed.
indicate rapid flow; narrow contours Racetrack Effect
indicate that the part is filling slowly The Racetrack Effect occurs when the flow races through the thick areas
of a mold cavity before the thin sections have filled - which can result in air
Diagram 2
traps and weld lines. Remedies may include changing wall thickness,
• In diagram 2, each flow path should end altering the location of the polymer injection, and using multiple polymer
with red contours injections.
Autodesk, (2017, Jan. 2), Fill Time Result, https://
1-2
*Remedies are suggestions. Consider all aspects of the mold design before
autode.sk/2Rqrujh making changes.
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Mold Flow Analysis Guide
Confidence of Fill Result
The Confidence of Fill Result displays the probability of plastic filling a region within the mold cavity under
conventional injection molding conditions. This result is derived from the pressure and temperature results.1
Things to Look For:
If the Confidence of Fill Result indicates that your part will have
medium or low confidence of fill - or is short shot - meaning the
flow of plastic does not completely fill the mold cavity, consider
these remedies*:
• Change the design to better balance flow paths
• Choose a different injection location to help ensure the part
is completely filled
Image courtesy of Autodesk • Re-evaluate the material selection/choice of plastic
• Change the processing conditions
Using this result:
To determine whether you can mold a good quality part, first
The colors displayed in the Confidence of consider which colors - and how much of each color, are visible
Fill Result indicate: on the Confidence of Fill Result. Then look at the Quality
Prediction result.
1. All green: Plastic fills the part easily and the
part quality will likely be acceptable. Combining these two results will help you to better understand
the risk of molding the part based on the 1-4 sliding color scale.
2. Some yellow: The part can be difficult to
mold, or quality is probably not acceptable.
As the percentage of yellow increases, the
difficulty in molding the part increases, and
the part quality decreases.
3. Some yellow and red: The part is difficult
to fill, or quality is probably unacceptable.
As the percentages of yellow and red
increase, the difficulty in molding the part
increase, and the part quality decreases.
4. Any translucent: The part cannot be
molded because a short shot will occur.
1 Autodesk, (2017, April 13) Confidence of Fill Result,
https://autode.sk/2RgcB2z
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Mold Flow Analysis Guide
Average Temperature Result1
The Average Temperature Result shows the average bulk temperature through the thickness of the part at the end
of fill.
The temperature at which polymer melts changes not only with
Using this result: time and location, but also with thickness during the entire injection
You can use the Average Temperature Result molding cycle.
as an alternate way of examining the flow
distribution. Average temperature represents the energy that is transported
through a particular location at a specific time.
Areas with continuous flow (heat convection)
typically have a higher Average Temperature, Hot spots, which are due to excessive viscous heating during the
which drops quickly when the flow in that area filling stage, are indicated on the average temperature contour.
stops.
Average Temperature is too low:
Things to Look For:
If the Average Temperature is too low in a thin A number of options are available to improve this result. Alterations
area of the part, hesitation or short shots can usually have side effects so after making changes, you should
occur. check to see whether other problems have been caused.
If the Average Temperature is too low in an Temperature Too Low Possible Problems
area where weld lines are present, the weld
lines may be worse.
Increase melt temperature. • May increase cycle time
Average Temperature is too high: • May cause material
degradation. Keep the
In areas where the Average Temperature is temperature within the
too high, material degradation and surface temperature limits specified in
defects may occur. the material information in the
database
To alleviate this:
• Make sure the Average Temperature is Increase mold temperature. May increase cycle time.
always within the recommended
temperature range for the polymer you are Decrease injection time. May cause excess shear in the
using gate if it is restrictive. Too much
• Consider redesigning the part geometry shear will cause degradation and
near the hot spot surface defects.
• Consider changing the process conditions
Differential temperature can also cause non- Increase the thickness in May cause a functional problem
uniform shrinkage and warpage problems. the area to permit flow. with the design and increase
cost.
The Average temperature result should be
For hesitation in thin areas. See Hesitation.
examined in conjunction with the Frozen layer
fraction at end of fill result.
May cause hesitation or other
Move the gate away from
problems elsewhere in the part.
Any section of the mold with an average the hesitation area.
temperature that is below the material
transition temperature, and a frozen Temperature Too High Possible Problems
percentage of greater than 25% may not be
packed properly, which can lead to shrinkage Increase the injection time. May increase cycle time.
and warpage problems.
1Autodesk, (2015, Apr. 27), Average Temperature Result
https://autode.sk/375RQh1
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Mold Flow Analysis Guide
Orientation at Skin Result1
The Orientation at Skin Result provides a good indication of how molecules will be oriented on the outside of
the part, showing the average principal alignment direction for the whole local area at the end of filling.
Using this result: It is important to orientate the molecules correctly to
ensure the mechanical quality of a hinge. The injection
The Orientation at Skin Result is useful for estimating
locations must be placed in positions that produce a
the mechanical properties of a part. For example, the
consistent molecular orientation, as shown in the following
impact strength is typically much higher in the diagram on the left. The diagram on the right shows
direction of molecular orientation at the skin. inconsistent molecular orientation, which leads to lower
part quality.
Fiber-filled Polymers
When using fiber-filled polymers, the tensile strength
is also higher in the direction of orientation at the skin
because the fibers on the surface are aligned in that
direction.
The skin orientation generally represents the direction
of strength. For plastic parts that must withstand high
impact or force, the gate location can be designed to
give a skin orientation in the direction of the impact or
force.
Image courtesy of Autodesk.
Unfilled Polymers
The linear shrinkage of a part also depends on the skin
orientation. For unfilled polymers, the shrinkage in the
Things to look for:
direction of the skin or flow orientation is greater than
When viewing the Orientation at Skin Result, watch for
in the direction of the core or transverse orientation.
the following:
This situation may be reversed when using fiber-filled • Unbalanced flow
polymers due to the low shrinkage and stiffness of the • Inconsistent orientation
fibers in the direction of skin orientation.
Note: More accurate predictions of fiber orientation
can be obtained from a Fiber analysis.
Unfilled Polymers
The linear shrinkage of a part also depends on the skin Without rigorous Fiber orientation analysis, skin and
orientation. For unfilled polymers, the shrinkage in the core orientations provide a good indication of how
direction of the skin or flow orientation is greater than molecules will be aligned in non-fiber filled materials.
in the direction of the core or transverse orientation.
This result shows how fibers will be oriented at the skin
This situation may be reversed when using fiber-filled when using a fiber-filled material.
polymers due to the low shrinkage and stiffness of the
fibers in the direction of skin orientation. Note: Core fiber orientation may be different to skin
fiber orientation.
Compare the Orientation at skin result with the Fill
Time Result to identify unbalanced flows in the part.
Because the melt freezes very quickly when it contacts
the mold for the first time, the velocity vector provides
the most probable molecular orientation at the skin. The
magnitudes of these vectors are normalized to one and
are displayed multiplied by the given scale factor. Skin
1 Autodesk, (2014, Oct. 6) Orientation at Skin Report, https://
orientation is determined by the velocity direction when
autode.sk/3asn4kn
the melt front first reaches a given location.
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Mold Flow Analysis Guide
Air Traps1
The Air Traps Result shows how severe the air traps will be and where they are likely to occur on the part.
Overview:
An air trap occurs where the melt traps and compresses a bubble of air or gas between two or more converging flow
fronts, or between the flow front and the cavity wall. Typically, the result is a small hole or a blemish on the surface of
the part. In extreme cases, the compression increases the temperature to a level that causes the plastic to degrade or
burn.
Air traps are often due to converging flow fronts caused by racetrack or hesitation effects, or by non-uniform or non-
linear fill patterns. Even when the part has balanced flow paths, inadequate venting can cause air traps to occur at
the ends of flow paths.
For a Midplane or Dual Domain model, the Air Traps Result shows a thin, continuous line wherever an air trap is likely
to occur. For 3D models, it displays a contour plot indicating the probability of an air trap occurring.
The Air traps result can reveal the following problems in your part:
• Burn marks caused by air in an air trap,
which ignites under pressure and burns the
plastic
• Short shots caused by the incomplete filling
of the part; if a air trap is not vented and
not compressed quickly enough to cause a
burn mark, it may cause a short shot or
Image courtesy of Autodesk. leave bubbles of air or gas in the plastic
part
Using this result • Other surface blemishes caused by air traps
The Air traps result shows how severe the air
traps will be and where they are likely to occur
on the part. Air traps may be acceptable if Things to look for:
they occur on a surface that does not have to
be visually perfect . The following methods can be used to prevent air traps:
The Fill Time Result is used in conjunction with • Use flow leaders or deflectors
the Air Traps result to confirm the filling • Increase the injection speed to eliminate air
behavior and assess the likelihood of air traps traps caused by converging flow fronts and
appearing. hesitation
• Decrease the injection speed to reduce air
The air trap plot is used to determine the traps caused by poor venting, and to
probability of an air trap occurring at a prevent burn marks
particular location. • Move the injection locations so that the air
traps form in areas that are easy to vent,
A higher value indicates a higher probability such as the parting plane
that an air trap will occur, and a lower value
indicates a lower probability that an air trap
will occur.
1Autodesk,(2015, May 20), Air Traps Result, https://
autode.sk/2tTK6zS
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Mold Flow Analysis Guide
Weld Lines Result1
The Weld Lines Result displays the angle of convergence as two flow fronts meet. The presence of weld lines
may indicate a structural weakness and/or a surface blemish.
Using this result Overview:
To examine the processing conditions under
The term “weld line” is often used to mean both weld and meld
which the weld lines occurred, you can change
lines. The only difference between them is the angle at which they
the weld line properties.
are formed; weld lines form at lower angles than meld lines. Weld
lines can cause structural problems and make the part visually
Weld lines can be moved by changing the fill
unacceptable, but they are unavoidable when the flow front splits
pattern to make the flow fronts meet at a
and comes together around a hole, or if the part has multiple
different place.
gates.
To move weld lines:
Consider the processing conditions and position of the weld lines
• Alter the gate locations to determine whether the weld lines will be high quality. Weld and
• Change the thickness of the part meld lines should be avoided, particularly weld lines in areas that
require strength or a smooth appearance.
To improve the quality of weld lines:
• Increase the melt temperature, injection Note: For Midplane or Dual Domain studies, this result is the same
speed, or packing pressure. This will enable as a custom weld line plot with a meeting angle of 135 degrees.
the flow fronts to weld to each other more For a different meeting angle, create a custom weld line plot and
effectively specify the meeting angle.
• Increase the diameters of gates and runners
to make it easier to pack the part Processing conditions help to determine the quality of weld or
• Move injection locations to make weld lines meld lines. Weld line strength is influenced by the temperature at
form closer to the gates. The weld line is which the weld line is formed and the pressure exerted on the
then created with a higher flow front weld until the part freezes; pressure is 0 at the weld line. Typically
temperature and is packed with more a “good” weld will occur if the temperature of the melt at the
pressure weld line as it forms is no more than 20°C below the injection
• Move injection locations to make flow temperature.
fronts meet more obliquely, turning the
weld line into a meld line
• Place a vent in the area of the weld line.
This will remove air traps, which could
Things to Look For:
further weaken the weld line
• Optimize the design of the runner system The Weld Lines Result helps you identify the following problems:
• Reduce runner dimensions and maintain the
same flow rate. Shear heating can then be • Structural problems: The part may be more likely to
utilized to increase the melt temperature at fracture or deform at a weld line, especially if the weld
the flow front line is of a low quality. This weakness is a more
serious problem in areas of the part that are subject
Solving one problem can introduce other to stress
problems to the injection molding process.
Carefully consider all the relevant aspects of the • Visual defects: A weld line can cause a line, notch, or
mold design specification before choosing an color change on the surface of the part. If the weld
option. line is positioned on a non-critical part surface, such
as the bottom, this may not be a problem
Note: Accurate weld line prediction depends
on the quality of the mesh. Refining the mesh
can improve weld line prediction, especially
around holes.
1Autodesk, (2017. March 28) Weld Lines Results,
https://autode.sk/35TKcEN
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Mold Flow Analysis Guide
Sink Marks Estimate and Sink Marks Shaded Results1
Displays simulated sink marks on the part. These are two different visual interpretations of the same result.
Overview: Generally, if the thickness of the rib is less than or equal to 60
percent of the main wall section, there is not likely to be any
The Sink Marks Estimate Result displays the significant sink marks.
calculated depths of sink marks in the part and
provides a legend to interpret the depth If it is not possible to remove or reduce a sink mark, you can
differences. conceal it. This can be done by adding a design feature, such as a
series of serrations on the area where it occurs.
The Sink Marks Shaded Result displays the sink
marks on the model to represent how the part
will actually look, as shown in the following Things to Look For:
diagram.
The following solutions can reduce the occurrence of sink marks:
1. Alter the part design to avoid thick sections and reduce the
thickness of any features that intersect with the main surface.
2. Relocate the gate to or near the problem areas. This enables
these sections to be packed before the thinner sections
between the gate and the problem areas freeze.
3. Increase the size of gates and runners to delay the gate
Image courtesy of Autodesk.
freeze-off time. This enables more material to be packed into
These sink mark results indicate the presence the cavity.
and location of sink marks and voids likely to 4. Decreasing the melt and mold temperature may be sufficient.
be caused by features on the opposite face of Alternatively, a less viscous melt can be used.
the surface. 5. Note: Because sink marks occur during packing, the most
effective way to reduce or eliminate them is to control the
Sink marks typically occur in moldings with packing pressure correctly. Use a more comprehensive
thicker sections, or at locations opposite ribs, simulation package such as Autodesk Moldflow Insight, to
bosses, or internal fillets. These results do not determine the effects of packing on sink marks.
indicate sink marks caused by locally thick
regions.
Note: Although the result cannot predict
whether a sink mark or a void has occurred,
sink marks are the more likely option.
Using this result
Because sink marks are a visual defect rather
than a structural defect, the result should be
evaluated against the part's visual design
specifications. Lighter colors and textured
surfaces tend to make sink marks less visible.
1Autodesk,(2017, Jan. 2) Sink Marks Estimate and Sink
Marks Shaded Results, https://autode.sk/35PqMRx
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