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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

Moldflow Case Studies


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Failure Analysis

Material Evaluation

Design Evaluation

Moldflow Analysis

Subrogation Engineering

On-Site Consulting

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Moldflow Analysis Moldflow Insight 2011

Moldflow Analysis

What The Madison Group does is simple. We solve plastic problems while keeping in mind your desire to drive product development towards lower costs and higher quality. In today's marketplace, time is of the essence. It is critical when designing plastic parts that one understands how the plastic will behave in the environment and the operational load to which it will be subjected. With multiple Certified Moldflow Consultants our knowledge of plastic processing and Moldflow's technology ensure that the design and mold will work right the first time.

The Madison Group Can Provide Injection Molding Analysis of:

I was very pleased with the flow analysis. It did exactly what it said it would do. We made the gate changes and we are now running with 2 gates instead of 4 plus we are de-gating with our robot. With the changes made we are able to group up that mold with 2 other molds and use only 1 operator for all 3 presses saving us the cost of an extra operator. Thanks for a great job!

Kevin Gauthier, Research Products Corp.

Fill/Pack Analysis

Fill Pack Analysis

Manufacturing a quality product starts with an optimized filling and packing stage. Fill/Pack analysis allows the designer to see the resin behavior in the mold and determine the process parameters required to fill the part. The Madison Group can provide the following information from performing a fill and pack analysis:

Cooling Analysis (Steady State and Transient Analysis)

Study State Analysis

The cooling phase is often the critical phase for determining cycle time. Analyzing the cooling phase can help determine the coolant conditions needed to maximize the efficiency of the proposed cooling layout. Effectiveness of high conductivity mold inserts, and cooling components such as baffles and bubblers can be compared beforehand so that costly and difficult changes to the mold can be avoided. A cooling analysis can assist in:

Warp Analysis

Warp Analysis

Designers use injection molding to mass produce high precision intricate parts. After designing the part it is important to ensure the part can be manufactured within tolerance and will not exhibit excessive warp. Warp is related to several factors including part design, resin selection, fiber orientation, the molding process, or cooling system.

Performing a warp analysis helps isolate the reasons for part distortion after molding and creates a solid foundation for making changes to reduce or eliminate the distortion. Using warp analyses can assist in identifying design and process variations that cause warp, conduct material comparison, and find solutions to ensure the manufacturing quality parts.


Coupled Structural Analysis (FEA)

Structural Analysis

As plastics are being integrated and used in more performance demanding applications engineers need a method of evaluating the design of a part to ensure it will performed for its intended lifetime. The Madison Group uses structural finite element analysis (FEA) to predict how the part will respond in its environment. Due to the relatively complex nature of polymers structural analysis allows our engineers to quickly and efficiently evaluate each aspect of the part design:

These factors are inter-related and need to be considered collectively. The Madison Group’s extensive knowledge of these factors allows for solutions to be found quickly and helps bring its clients to market faster.

Information that is commonly extracted from these analyses include: