Techniques developed for the three-dimensional simulation of gas assisted injection moulding of complex parts are outlined. Solutions for the coupled flow and heat transfer of polymer and gas provide simulations of polymer melt flow, identifying potential weld lines and gas traps; primary gas penetration, where the gas cores out the part; and the packing stage, where secondary gas penetration is modelled as the plastic cools and shrinks. Simulation results are in the form of fully featured 3-D animations, giving highly realistic images of flow and temperature fields. Industrial applications are shown, including automotive and other handles, and simulations are compared with full/short shot and finished parts. Examples of some conclusions drawn from the simulations regarding a need for part re-design or alternative processing conditions are described.
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