Cadmould 2K & Insert: Multi-Component Injection Molding Simulation

In modern manufacturing processes, combining multiple materials or embedding metal inserts into plastic parts has become increasingly common. However, complex thermal and mechanical interactions often lead to serious defects such as core deformation or part warpage. To address these challenges, the Cadmould 2K & Insert module was developed as a powerful support tool for mold and tooling engineers.

1. Challenges in Multi-Component Manufacturing

When producing multi-component plastic parts (2K) or applying insert molding techniques, high-pressure melt flow can displace the inserted components, leading to core shift and dimensional inaccuracies. If these effects are not evaluated early, such defects are often discovered only after mold trials—resulting in significant time loss and extremely high rework costs.

Cadmould 2K & Insert enables manufacturers to predict these behaviors in a virtual environment, allowing engineers to proactively adjust the design before committing to physical tooling and production.

2. Benefits of Cadmould 2K & Insert

Applying this solution delivers five key benefits:

• Improved part quality: Analyze and minimize shrinkage and warpage in multi-component molds.
• Accurate core-shift prediction: Detect insert displacement caused by high-pressure molten polymer flow during injection.
• Optimized injection molding parameters: Support fine-tuning of gate locations, injection pressure, and mold design to reduce deformation risks.
• Seamless integration: Works in perfect coordination with other simulation functions such as Fill, Pack, and Warp to model the entire molding process end to end.
• Thermal optimization: Effectively balance insert pre-heating and cooling strategies for stable, repeatable results.

3. How the Software Works

To deliver accurate and reliable results, Cadmould 2K & Insert follows a robust, structured simulation workflow:

• Pressure and thermal effect modeling: Simulates realistic filling behavior and pressure distribution as the molten polymer flows around inserts.
• FEM-based deformation simulation: Uses advanced Finite Element Methods (FEM) to predict how inserts will shift, deform, or rotate under shear forces and injection pressure.
• Post-simulation analysis: Aggregates results from all stages to evaluate the final dimensional stability and quality of the molded part.

4. Core Features of the Module

4.1 Core-Shift and Insert Deformation Analysis

Cadmould 2K & Insert goes beyond melt-flow simulation by calculating the mechanical strength of inserts based on stress–strain curves. This enables engineers to identify potential misalignment or positional deviations that could lead to defective parts.

4.2 Multi-Material Interaction Simulation

The module computes how different materials—such as metal inserts and thermoplastics—respond to thermal and mechanical loads during overmolding. This capability is especially critical when working with materials that have significantly different coefficients of thermal expansion.

4.3 Optimization of Gating and Cooling Strategies

Based on simulation data, users can adjust gate locations or modify packing pressure to minimize forces acting on inserts, while simultaneously improving the efficiency of the mold’s cooling system.

5. Real-World Industrial Applications

The Cadmould 2K & Insert solution is widely used across high-precision industries:

• Automotive & Aerospace: Manufacturing precision hybrid components and lightweight assemblies with high structural strength.
• Medical & Electronics: Producing plastic–metal connectors, electronic housings, and micro-components manufactured using overmolding processes.
• Consumer Goods: Developing soft overmolded grips and reinforced plastic–metal interfaces for enhanced durability and ergonomics.

6. Integration Capabilities and the Cadmould Ecosystem

Cadmould 2K & Insert is part of the comprehensive simulation ecosystem developed by SIMCON. The module integrates seamlessly with:

• Fill & Pack – To analyze melt-flow behavior and packing pressure effects
• Part FEM – To evaluate surface quality and structural integrity of parts
• Thermal Mould Advanced – To perform advanced heat-transfer analysis for mold cooling systems

Currently, this module is available in the Cadmould Flex Advanced, Cadmould Flex Premium, and Cadmould Flex Enterprise license packages, or it can be provided as a flexible add-on tailored to the specific needs of the enterprise.

7. Frequently Asked Questions about the Cadmould 2K & Insert Module

7.1 Does the 2K & Insert module support calculations for metal inserts?

Yes. This is one of the most powerful capabilities of the module. The software allows you to define the material properties of inserts (such as stiffness and thermal conductivity of steel, copper, aluminum, etc.). Based on this, it simulates how heat is transferred from the molten plastic to the insert and how the insert resists the plastic flow.

7.2 If Fill and Pack modules are already available, why is the 2K & Insert module still needed?

Standard Fill and Pack modules only simulate plastic flow in an empty mold cavity. For products with inserts or overmolding, the thermo-mechanical interactions between components are extremely complex. Only the 2K & Insert module has the necessary algorithms to accurately calculate uneven shrinkage and residual stresses at the interfaces between different materials.

7.3 Does the software suggest gate locations to minimize insert deformation?

Yes. Based on pressure simulation and Core Shift results, engineers can test multiple gate locations within the software. Cadmould Flex displays the corresponding deformation results, helping users select the optimal solution to balance pressure on the insert and ensure the highest product quality.

*Content compiled from: simcon.com

In the era of smart manufacturing, mastering multi-component simulation technology is a critical success factor for mold-making enterprises. Cadmould 2K & Insert is not merely a calculation tool, but a strategic solution that helps reduce risks, optimize productivity, and ensure top-level product quality. To receive consultation and experience the powerful features of Cadmould 2K & Insert, please contact the technical team at SDE Tech.

• Email: sales@sde.vn
• Hotline/Zalo: 085 256 2615 – 0909 107 719\

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