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Warpage displacement on the simplified goggles model |
As demand for high-precision plastic components in the medical industry continues to rise, manufacturers are under increasing pressure to improve molding efficiency while minimizing defects. Two-shot (2K) injection molding offers a path forward for producing lightweight, ergonomic medical products — but it also introduces challenges in material compatibility, warpage, and short shot control.
A recent study led by Upoma Saha of Grand Valley State University and Dr. Wael Mokhtar of Bowling Green State University highlights how Moldex3D was used to simulate and optimize the injection molding process for polycarbonate safety goggles. By combining CAE analysis with Taguchi Design of Experiment (DOE), the research team achieved a 25% reduction in warpage and a 3% improvement in short shot performance.
The study demonstrates how simulation not only predicts critical defects in plastic injection molding but also enables parameter-driven optimization, accelerating product development and improving yield—essential outcomes for the fast-paced medical device sector.
