Before computer simulation became available, the large number of interactive process variables limited the molding engineer's ability to accurately predict the outcome of a particular set of design parameters, material selections, and processing conditions. Furthermore, many are not aware of the limitations of plastics that are imposed by inappropriate design and processing. The results were often poor performance, over-design, high costs, and missed project milestones. In today's competitive climate, these approaches have become increasingly inadequate and inefficient when applied to the molding of larger, more complex, more precise, and costlier parts, to the processing of new materials, or to emerging processes. Since the 1960s, substantial progress has been made in CAE technology for both thermoplastics and reactive materials, removing most of the guess work from the design process.
Engineers can perform molding trials on the computer before the part design is completed.
Process engineers can systematically predict a design and process window, and can obtain information about the cumulative effect of the process variables that influence part performance, cost, and appearance. In addition, process simulation can be used as direct feedback to guide product, tooling, and process design efforts. CAE makes it possible to replace traditional, sequential decision-making procedures with a concurrent design process, in which all parties can interact and share information. Currently, science-based CAE software products are becoming more and more accurate and accommodate detailed descriptions of the process and physical phenomena. Mold designers and process engineers have been advantageously and cost-effectively employing advanced CAE technology to improve productivity and process consistency.