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The Madison Group

Putting Years of Plastics Engineering Experience To Work For You

2615 Research Park Dr.
Madison, WI 53711
Phone: (608) 231-1907
Fax: (608) 231-2694


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Case Studies

Case Studies

Our case studies exemplify some common issues that our engineers encounter and highlight how we were able to help our customers find a solution. Please review them by following the links and let us know if you have any questions. Call The Madison Group at (608) 231-1907, or contact us via our information request service for a no-obligation consultation. We'll be glad to speak with you about resolving any concerns you may have with your plastic part design or material.

Lightweighting of a Plastic Container

Key Words: Lightweighting, Virtual DOE, Injection Molding Simulation
Read the Case Study

Fuel Filter Filling Analysis

Key Words: Moldflow, Nylon, Knit line, Weld line, Air trapping
Read the Case Study

Actuating Lever Failure

Key Words: Failure, Environmental Stress Cracking
Read the Case Study

Rain Barrel Analysis

Key Words: Failure, Creep, FEA, Design Evaluation
Read the Case Study

Water Tubing Failure

Key Words: Failure, Tubing, Degradation, UV
Read the Case Study

Acetal Housing

Key Words: Warpage, Moldflow, Acetal, Cooling
Read the Case Study

Co-Injection Molding Analysis

Key Words: Furniture; Flow leader; Co-injection
Read the Case Study

Knitline Failure Analysis

Key Words: Failure, Cross-sectioning, Knitline
Read the Case Study

Runner Balance Analysis

Key Words: Family Mold, Runner Design, Moldflow
Read the Case Study

Snap Fit Failure

Key Words: Failure, Snap Fit, Contamination, FTIR
Read the Case Study

Creep Lifetime Prediction

Key Words: Creep, Lifetime prediction, Dynamic Mechanical Analysis
Read the Case Study

Other Case Studies

Case StudyFailure of PVC Pipe

Case Study(HDPE) Outdoors Application

Case StudyWater Filter Housing Failure

Case StudyPolycarbonate Bottle Cap Failure

Case StudyCo-Injection Simulation of Luggage Carrier

Case StudyKnit Line Relocation for Automotive Body Panel

Case StudyCompression Molding of Radiator Support

Case StudyLawn Mower Wheel Failure