The magic is in the details
Computer-aided design allows us to work on the finest details to optimize your product at the earliest stages. It lets us avoid pitfalls in tool design, production processes and post production performance. Accelerate time to market. We even maintain a database that correlates computer results with end-use performance results. This effort further increases the accuracy of our predictive CAE work.
Bring us the outer shell of a concept. We can fill it in. Ribs. Cutouts. A structure that will hold up to the design criteria or integrate in performance. Reduce the number of parts or steps in assembly. Our state-of-the-art technology and tools provide you with a complete and cost effective product from conception to production.
For example, our comprehensive portfolio of molding process-related software tests the manufacturability of a part and assists with mold design before the mold tool is ever cut. The software helps us eliminate guesswork, as well as reduce mold costs, molding cycle time and secondary operations. The code can also improve aesthetics by predicting weldlines and air traps.
The mold simulation process has been taken to the next step by developing a proprietary glass fiber orientation prediction software to facilitate more accurate simulations of induced part warpage due to random fiber orientation and distribution during the molding process.
Our engineers complement the software's capabilities with real-world molding experience. They not only know how to run the code, they understand what it takes to bridge the gap between theory and practice.
Or how about our Finite Element Analysis (FEA) that provides predictive structural analysis of parts and assemblies under in-use stress loading conditions? We also employ FEA in failure analysis and optimization studies. Capabilities include leading edge codes for linear, non-linear and dynamic analysis. The range of software codes and proprietary methods at BASF enable us to efficiently develop pre-processing models, perform load and stress analysis, and then post-process for visual evaluation of actual stresses and part topology optimization. To tie predictive modeling more closely to real part performance, we have established a database correlating FEA results with physical testing of actual parts.
Then there's noise, vibration and harshness (NVH). Plastics have inherent NVH advantages over metal. Our sophisticated computer-aided design, analysis and testing is conducted in an integrative approach. We marry the virtual world of experimental noise and frequency signature measurement with real experimental input derived from physical testing on real parts/systems or in lab settings. We even perform testing of prototype parts on board of vehicles or in end-use equipment.
We utilize signal analysis, laser vibrometry and other advanced vibration and acoustic measuring techniques to complement and validate CAE prediction of NVH characteristics.
Optimized airflows impact on noise, energy-efficiency and size fluid-flow applications, including comfort conditioning, fans, motors and automotive components.
Computational Fluid Dynamics (CFD) studies not only permit early identification of potential problems — even before prototypes are built — but also provide design direction where physical size or prototyping costs prove to be prohibitive. We can supplement computer results with end-use testing of molded parts.
We perform steady, quasi and non-steady state studies and correlate CFD modeling results to a growing database of actual part airflow performance. We can also apply our proprietary algorithms to optimize part performance and development.
Need a prototype in three to five days? You're in the right place. When it comes to testing injection molded parts, there may be no substitute for the real thing, but rapid prototyping can put you on the right track faster by getting you a 3D part that can convey the real feel of a "hold in your hands" concept.
We can produce 3D rapid prototypes from your CAD files in common formats such as IGES, STEP or STL on our own Stereo Lithography Apparatus (SLA).
SLA rapid prototype parts can function as a tremendously useful communications tool for everyone involved in the product development process. Your customer, design and manufacturing engineers, mold makers and injection molders are just a few of the key personnel that can hold the design in their hands — literally created overnight.
Working with other materials is as important to us as working with customers. That's why we've explored, developed, refined and revolutionized several assembly and joining technologies, to ensure that parts made from our materials work with other materials as well as they work with themselves. One example? We pioneered revolutionary work in snap-fit design, revising classical physics theory on cantilever design and developing new algorithms for more accurate stress and strength calculations.
We can also help with tool development, product performance optimization and cycle times.
Mold Filling Software
- MoldFlow Filling
- MoldFlow Cooling
- MoldFlow Shrinkage & Warpage
- MoldFlow Flow 3D Analysis
- MoldFlow Fusion
- MoldFlow Fiber
- MoldFlow Gas-assist
- MoldFlow Co-injection
- Moldex 3D
- BASF Proprietary Fiber
- Ideas Master Series
- HyperWorks (with OptiStruct)
- CFD 2000