Fill Results - Solidworks Plastics

Fill Time:
The fill time plot displays the profile of the plastic melt as it flows through the mold part cavity during the filling stage of
the injection molding process. The blue regions indicate the start or beginning of the flow front. The red regions indicate
either of the following:
The flow front position at any given time interval during an animation of the filling stage
The end of fill when the flow has stopped, even if the software detects a short shot
Two views of the same part with a centrally located injection location.
The filling pattern radiates out from the center (blue) to the end of fill (red) located at each corner of the part. Since fill
time is a function of flow length (among other things), the corners that are the furthest away from the injection location
are the last to fill. The color scale located to the left of the part indicates the time it takes for the flow front to reach a
given region of the cavity.
SOLIDWORKS Plastics software automatically calculates a recommended fill time and volumetric flow rate. The filling
time can have a significant effect on most results generated from a simulation. For example, a longer fill time may reduce
injection pressures, shear rates, and shear stresses, while a shorter fill time can increase injection pressures, shear
rates, and shear stress. Note - changing the fill time and running a new simulation overwrites existing results.
To change the fill time:

1)
Under INPUT, Process Parameters, double-click Fill Settings.
2)
Clear Auto.
3)
For Filling Time, enter a value in seconds.
4)
Click OK
5)
Under RUN, double-click a fill option:
Flow
Flow + Pack (SOLIDWORKS Plastics Professional and Premium only)
6)
Click Yes, when prompted to replace the fill results.
Injection locations:
The injection location is where the melted plastic enters a mold cavity. The last area of a cavity to fill is called the end of
fill, which is typically located furthest from the injection location or in the thinnest wall sections. When a mold cavity
cannot be filled by an injection location located on either end of the part because the flow length is too long, you should
move the injection location to a different location that results in shorter flow paths.
Short shot resulting from an extreme flow length.
Moving the injection location to a central location will also minimize injection pressure requirements and result in a more
uniform filling pattern from the injection location to the end of fill. In this example, even though the melt has to travel in
two directions the flow length is cut in half, allowing the cavity to fill completely. Note that a change in injection location
might result in non-uniform filling of the cavity, where the melt reaches one end of the cavity before the other.
Non-uniform filling of the cavity as pictured, the bottom of the part fills before the top.
You can review the fill time plot to ensure that the extremities of the cavity fill at the same time. Use the results found
from the initial change in injection location to find the optimum injection location. The injection location located at the
middle of the handles left edge fills the lower section before the head of the drill casing. This uneven filling pattern will
likely result in non-uniform packing and volumetric shrinkage and could cause post-molding problems (such as warpage)
in the part.
A uniform filling pattern both the top and bottom of the cavity fill at the same time.
Choosing an injection location further up along the left side of the drill casing results in uniform filling patterns from the
injection location to the end of fill.
To reposition an injection location:

1)
Under INPUT, Boundary Conditions, double-click Injection Location.
2)
To delete the existing injection location, click either:

Delete Injection Location
Delete All Injection Locations
Note: The previous injection location is highlighted in blue, indicating that you can either move or
delete it.
3)
Click Yes, when prompted to delete an injection location.
4)
In the Command Manager, click Mesh Model
5)
Double-click a Node located in the mesh to select the new injection location.
6)
To define the new injection location, click Add Injection Location
to display the mesh.
Note: The highlight color of the injection location will change from blue to light purple.
7)
Click OK
8)

Flow
9)
You should examine the fill time plot and the pressure at end of fill plot to ensure uniform filling patterns and pressure
distributions. A uniform filling pattern is when both melt fronts reach their end of fill locations at the same time and at the
same pressure. The blue regions from the pressure at end of fill plot should occur at the locations where the red regions
from the fill time plot occur. Doing so will reduce post molding problems with the final product.
Pressure at end of fill and fill time plots from the same simulation that display uniform filling patterns and pressure
distributions.
To display a section view of fill time:

1)
Under RESULTS, double-click Fill Results.
2)
Click Fill Time.
3)
Click Clipping Plane Mode
The clipping plane mode of the fill time plot displays the internal flow front during the filling stage (Solid Mesh only).
Animation of Fill Time:

You can display the melt flow front position during the filling stage by animating the fill time plot.
To animate the fill time:

1)
2)
Click Play
3)
To pause the animation, click Pause
.
.
4)
To stop the animation, click either:

Stop
clear Repeat
5)
To view the filling profile as contour lines (Shell Mesh) or a wireframe cavity (Solid Mesh), click
Isosurface Mode
6)
For a section view of the filling stage (Solid Mesh only), click Clipping Plane Mode
7)
To slow down or speed up the animation, click Stop

click Play
, slide the Speed scale to the desired rate, and
To display the fill time manually:
1)
2)
Select + slide the Max or Min scale to move through the fill time.
3)
After selecting the Max or Min scale, you can press the directional arrows on your keyboard to adjust
the fill time display.
Three manual display views of the fill time.

4)
5)
If an animation is currently playing, click Stop

To view a contour line plot, click Isosurface Mode
only).
before sliding the Max or Min scale.

and slide the Max or Min scale (Solid Mesh
Three manual display views of the fill time using wireframe mode.
Velocity Vector at End of Fill:

The velocity vector at end of fill plot provides in indication of the molecular orientation that occurs as the melted plastic
flows through the mold part cavity.
To display velocity vector at end of fill:

1)
2)
Select Velocity Vector at End of Fill.
View of the velocity vector at end of fill plot.
Note: For fillers with high aspect ratios, mechanical properties in the direction of flow differ from those transverse to the
direction of flow. A material with a high aspect ratio filler will typically have improved properties in the flow direction and
lower mechanical properties transverse to the direction of flow. Spherical fillers result in a more uniform distribution of
mechanical properties in both the direction of flow and transverse to the direction of flow.
Weld Lines:
Weld lines are formed when two or more plastic melt flow fronts come together and they can be caused by mold shut-off
surfaces, mold core features, multiple injection locations or wall thickness variations that cause flow front promotion or
hesitation. Weld lines are typically weaker than areas without weld lines and they often result in cosmetic defects. They
can also act as stress concentrators in the molded part. Weld lines generally form 180O opposite of the point where the
melt front makes contact with the standing core of a shut-off surface. Weld lines are unavoidable in parts with throughholes or multiple injection locations. So while you might be able to move the injection location to change the weld line
location, the weld line cannot be eliminated.
To display weld lines:

1)
2)
Select Weld Lines.
View of the weld line plot.
Air Traps:
If the air in the mold cavity cannot be vented to the atmosphere during the filling stage, the trapped air can prevent the
plastic material from filling the volume where the air trap is located. This can result in incomplete filling and packing in the
air trap location or even a through-hole in the part due to the trapped air. In a worst case scenario, the trapped air can
get compressed, combust and cause burn marks on the molded part and/or damage the mold core and cavity surfaces.
Placing a parting line vent, ejector pin, cavity insert, or a porous metal insert at these locations can help reduce or
prevent air traps from occurring, but it is best to avoid them completely.
To display Air Traps:

1)
2)
Select Air Traps.
View of Air Traps superimposed over a Fill Time plot.
Pressure at End of Fill:

During the filling stage, the forward injection velocity of the reciprocating screw is controlled, which results in the pressure
required to fill the cavity at that velocity. The injection pressure is propagated through the molten plastic and results in a
pressure drop distributed along the length of flow. The pressure at the end of fill is a very good indication of how evenly
the cavity has filled.
Uneven and even pressure at end of fill plots.
In the first example, an injection location was placed in the middle of an asymmetrical handle. The pressure at end of fill
plot shows an uneven distribution of pressure throughout the cavity. The second example shows that repositioning the
injection location slightly to the right results in an even pressure distribution throughout the cavity. Even pressure at all
end of fill locations will improve the effects of packing pressures and cooling throughout the molded part. You should
attempt to place the injection location where the pressure at end of fill plot displays an even pressure distribution.
Note: Pressure drop is a function of flow length, part wall thickness, and melt viscosity. High pressures are required to fill
thin-walled injection molded parts, since the flow resistance through the smaller cross sectional area is greater. When
SOLIDWORKS Plastics detects a short shot, try the following:
1)
Reposition the injection location: If the injection location is near the end of a part, the flow length is essentially the
entire length of the part. Place the injection location near the middle of the part to reduce the flow length to about half the
length of the part. With the injection location located in the middle, even though the plastic flow must travel in two
directions, flow lengths and injection pressure requirements are reduced.
To reposition an injection location:

1)
2)
To delete the existing injection location, click either:

Delete Injection Location
Delete All Injection Locations
Note: The previous injection location turns blue, indicating that you can move it.
3)
Click Yes, when prompted to delete an injection location.
4)
In the Command Manager, click Mesh Model
5)
Double-click a Node located in the mesh to select the new injection location.
6)
To define the new injection location, click Add Injection Location
Note: The color of the injection location will change from blue to light purple.
7)
Click OK
8)

Flow
9)
2)
Change the fill time: A shorter fill time (or injecting faster) typically lowers the viscosity of the melted plastic, allowing
the material to flow further. Keep in mind that the shorter fill time may increase the injection pressure required, shear
rates and shear stress. The maximum injection pressure will be limited by the machine, while plastic materials have
maximum threshold values for shear rate and stress.

1)
2)
Clear Auto.
3)
For Filling Time, enter value for sec.
4)
Click OK
5)
Flow
6)
3)
Increase part wall thickness: To reduce injection pressures, you can increase the wall thickness of the solid model.
Then you would have to create a new mesh and run the analysis again. Increasing the part wall thickness will increase
cooling times and require more plastic material to mold the part.
To display a section view of pressure at end of fill:

1)
2)
Click Pressure at End of Fill.
3)
The clipping plane mode of pressure at end of fill displays the internal pressure distribution throughout the cavity at end
of fill (Solid Mesh only).
Temperature at End of Fill:

At the end of fill, the plastic in contact with the cavity wall freezes into a very thin frozen layer that has cooled down to the
temperature of the mold. The thickness of this frozen layer is independent of the thickness of the part wall. The thickness
is dependent on the melt and mold temperature differential and the material thermal conductivity.
The outside of the part cools, while the core volume remains molten, allowing the pressure of the pack stage to prevent
sink marks. Since the entire part surface temperature is equal to the mold temperature, the part appears blue.
View of temperature at end of fill.
To change the melt temperature:

1)
2)
For Melt Temperature, enter value for OC or OF.
Note: Materials in the SOLIDWORKS Plastics database have a maximum and a minimum melt
temperature value. This melt temperature range is the processing window that the material supplier
recommends for their material. A simulation cannot be run outside of the melt temperature range.
3)
Click OK
4)

Flow
5)
To display a section view of temperature at end of fill:

1)
2)
Click Temperature at End of Fill.
3)
The clipping plane mode of temperature at end of fill displays the internal temperature differential throughout the part
wall (Solid Mesh only).
Central Temperature at End of Fill:

The central temperature at end of fill plot indicates the melt temperature of the central position between the two surfaces
of a shell mesh. The plastic melt that is a further distance from the cavity wall will retain heat for longer periods of time.
The temperature of the molten core material may decrease quickly for a thin walled part, and SOLIDWORKS Plastics will
detect if a short shot has occurred.
View of central temperature at end of fill.
Average Temperature at End of Fill:

The average temperature at the end of fill plot indicates the average melt temperature between the two surfaces of a
shell mesh. If the temperature differential is non-uniform, sink marks and warpage may occur.
View of average temperature at end of fill.
Bulk Temperature at End of Fill:

During the fill stage, changes in the melt temperature are calculated using parameters such as time, distance from the
cavity wall, and part wall thickness. The bulk temperature at end of fill plot displays how much the melt has changed from
the set melt temperature. The Bulk Temperature plot indicates stagnant material, which has cooled significantly by the
end of fill, in blue. The plastic material with a velocity just before the end of fill, that retains heat, is displayed in red.
View of bulk temperature at end of fill.
To display a section view of bulk temperature at end of fill:

1)
2)
Click Bulk Temperature at End of Fill.
3)
The clipping plane mode of bulk temperature at end of fill displays the internal temperature differential throughout the
part wall (Solid Mesh only).
Flow Front Central Temperature:

The flow front central temperature plot represents the melt front temperature at the end of fill. As a result of fountain flow,
the flow front central temperature represents the temperature of the entire melt front. Consequently, the melt does not
change temperature until it makes contact with the mold wall.
The molten plastic flows through the center of the melt stream and then flows outward like a fountain.
View of flow front central temperature.
To display a section view of flow front central temperature:

1)
2)
Click Flow Front Central Temperature.
3)
The clipping plane mode of flow front central temperature displays the internal temperature differential throughout the
Temperature Growth at End of Fill:

In the injection molding process, the polymer melt undergoes shear heating during the fill stage. This increase in
temperature is due to elevated shear rates, which can raise the melt temperature in the cavity to above the set melt
temperature. The temperature increase can result from too short of a filling time, the use of small injection locations, or
material flow characteristics. Degradation of the material can occur under extreme conditions.
View of temperature growth at end of fill.

1)
2)
Clear Auto.
3)
4)
Click OK
5)
Flow
6)
To change an injection location dimension:

1)
2)
For Diameter, enter value for mm.
3)
Click Add Injection Location
Note: The injection location dimension located in the Injection Location window changes.
4)
Click OK
5)

Flow
6)
To display a section view of temperature growth at end of fill:

1)
2)
Click Temperature Growth at End of Fill.
3)
The clipping plane mode of temperature growth at end of fill displays the internal temperature differential throughout the
Shear Stress at End of Fill:

Shear stress is a measure of shear force per unit area. The direction of the shear force is parallel to the plane of the
force (the cavity wall), and can be thought of as the force melt uses to push the cavity wall in the direction of flow (not
pushing outward normal to the wall).
= F/A
= Shear stress
F = Applied force
A = Cross-sectional area of the material that is parallel to the applied force vector
Diagram of applied shear stresses: This diagram displays a moving wall sliding past a stationary fluid. As the wall
moves, it drags the fluid forward with the motion. The moving wall applies more shear stress to the fluid it is in contact
with, and applies minimal shear stress on the fluid furthest away in contact with the stationary wall. This example is
backwards when compared to plastic flow through a cavity. The wall does not move, the plastic melt moves along the
cavity wall. Think of the stationary wall in the diagram as the center of flow through a cavity. The material in the center of
flow moves with the least resistance, while the material along the cavity wall does not move due to the greater flow
resistance. Now take a cross-section of the melt, and imagine that extra force required to flow along the cavity wall is
related to the higher shear stresses. The material in the center of flow exhibits far less shear stress because there less
resistance to flow.
View of shear stress at end of fill.
To display a section view of shear stress at end of fill:

1)
2)
Click Shear Stress at End of Fill.
3)
The clipping plane mode of shear stress at end of fill displays the internal shear stress differential throughout the part
Note:
1 ) Your reported shear stress values should be less than the suggested maximum value for the plastic material used for
a given simulation. The maximum shear stress is often found at the injection location of the cavity. If the shear stress
values at the injection location are over the recommended shear stress value, you can increase the injection location
diameter in an attempt to reduce the maximum shear stress.
To check the recommended shear stress value:

1)
Under INPUT, Material, double-click Polymer.
2)
In the Polymer window, click the Polymer-Material Parameters tab.
Note: If the entire polymer-material parameter table is not visible, Click + Drag the
bottom right corner of the Polymer window to enlarge the viewing area. The shear stress
value is near the bottom of the table.
3)
Observe the Max. Shear Stress value for your material.
4)
Compare the Max. Shear Stress value to you simulated results
5)
Close the Polymer window.
To change an injection location dimension:

1)
2)
For Diameter, enter value for mm.
3)
Click Add Injection Location
Note: The injection location dimension located in the Injection Location window
changes.
4)
Click OK
5)

Flow
6)
2 ) To reduce shear stresses, you should increase the fill time which decreases injection velocity.

1)
2)
Clear Auto.
3)
For Filling time, enter value for sec.
4)
Click OK
5)
Flow
6)
3 ) High shear stresses are commonly found at sharp corners of a molded part. You can redesign the part with rounded
corners, reducing the shear stresses found at these locations. Then you would have to create a new mesh and run the
analysis again.
4 ) You can also try increasing the melt temperature to reduce the shear stresses, but increasing the melt temperature
increases the cooling time.
To change the melt temperature:

1)
2)
For Melt Temperature, enter value for OC or OF.
Note: Materials in the SOLIDWORKS Plastics database have a maximum and minimum melt
temperature value. This melt temperature range is the processing window that the material
supplier recommends for their material. A simulation cannot be run outside of the melt
temperature range.
3)
Click OK
4)

Flow
5)
Shear Rate at End of Fill:

Shear rate measures the velocity of a fluid layer passing over another layer of fluid at a different velocity. The frozen
plastic material in contact with the cavity wall does not move relative to the wall, which results in a shear rate of zero (0.0
1/sec). The molten plastic material just inside of the frozen layer moves over the frozen material, which yields a positive
shear rate (>0.0 1/sec). The shear rate continues to increase until a maximum is reached just inside the wall. Then the
shear rate begins to decrease toward the center of flow, reaching a local minimum in the center. This minimum occurs
because the polymer chains at the center of the flow move at the same speed and do not move relative to each other,
resulting in a zero (0.0 1/sec) shear rate.
Diagram of shear rate inside a cavity wall. This graph displays the value of relative movement of polymer chains as they
move past each other at different velocities. Polymer chains that slide past each other, moving at different velocities,
result in a positive shear rate. For example, the polymer chains that freeze along the cavity wall do not move (outer
minimums), but the molten polymer chains flowing past them induce an extremely high shear rate (maximums). The two
polymer chains at the center of flow move at the same velocity which does not produce any shear (center minimum).
View of shear rate at end of fill.
To display a section view of shear rate at end of fill:

1)
2)
Click Shear Rate at End of Fill.
3)
The clipping plane mode of shear rate at end of fill displays the internal shear rate differential throughout the part wall
(Solid Mesh only).
Notes:
1 ) Shear rate should be less than the suggested maximum value for the plastic material.
To check the recommended shear rate value:

1)
Under INPUT, Material, double-click Polymer.
2)
In the Polymer window, click the Polymer-Material Parameters tab.
Note: If the entire polymer-material parameter table is not visible, Click + Drag the
bottom right corner of the Polymer window to enlarge the viewing area. The shear rate
value is near the bottom of the table.
3)
Observe the Max. Shear Rate value for your material.
4)
Compare the Max. Shear Rate value to you simulated results
5)
Close the Polymer window.
2 ) To reduce shear rates, you can increase the fill time which decreases the injection velocity.

1)
2)
Clear Auto.
3)
4)
Click OK
5)
Flow
6)
Volumetric Shrinkage at End of Fill:

The volumetric shrinkage at end of fill can indicate areas of potential concern. High rates of shrinkage will occur in thick
sections of a plastic part which do not undergo a sufficient packing stage during the molding process. For example, if you
do not include a sufficient packing stage, high amounts of shrinkage will occur at the locations indicated in yellow and red
by the volumetric shrinkage at end of fill plot.
The first image displays the shrinkage that would occur if the packing stage was omitted from the injection molding
process. The second image displays how adding the packing stage can reduce the volumetric shrinkage found in the
part (SOLIDWORKS Plastics Professional and Premium only).
Note: Another form of shrinkage occurs in the form of voids. In a transparent molded part, sometimes bubbles can be
seen located inside the part wall. These bubbles are not air bubbles, they are vacuum voids. A void occurs when the part
surface is ridged enough to retain its shape and the molten core material tears itself apart from the inside, creating a
vacuum void. Voids also occur in opaque plastics parts, but they cannot be seen from the outside. The molded part must
be cut open to see if voids are occurring. Typically, voids occur in thicker sections, and in areas of changing wall
thicknesses (around the connecting rim of a boss, or along the transition from a part wall to a rib).
To display a section view of volume shrinkage at end of fill:

1)
2)
Click Volume Shrinkage at End of Fill.
3)
The clipping plane mode of volume shrinkage at end of fill displays the internal volumetric shrinkage throughout the part
wall (Solid Mesh only). The first image displays the fill stage only, the second image displays both fill + pack (Fill +
Pack SOLIDWORKS Plastics Professional and Premium only). The red regions found inside the part using the
clipping plane mode of volume shrinkage at end of fill might indicate the location of voids if an insufficient pack stage is
used during production.
Freezing Time at End of Fill:

The scale used for the freezing time at end of fill indicates the time required for the molten plastic material to cool down
to its glass transition temperature. The time required to reduce a molten melt to its glass transition temperature is not the
time required to cool the part to its ejection temperature. The material deflection temperature under flexural load is the
material ejection temperature. A plastic material deflection temperature under flexural load is roughly 2/3 the material
glass transition (Tg) or melt temperature (Tm) in degrees Kelvin. The required time depends on the temperature
differential between the melt temperature and the mold temperature, and on the thermal conductivity of the melt and
mold.
View of freezing time at end of fill.
To display a section view of freezing time at end of fill:

1)
2)
Click Freezing Time at End of Fill.
3)
The clipping plane mode of freezing time at end of fill displays the required internal freezing times throughout the part
Frozen Layer Fraction at End of Fill:

When plastic melt makes contact with the mold wall, a thin layer of the melt instantly freezes along the cavity wall. This
layer of solidified plastic is called the frozen layer fraction. It is a friction because the majority of the plastic located in the
central core of the part wall remains molten. At the instant the cavity is completely filled, the frozen layer closer to the
injection location will be thicker than the frozen layer in the area around the end of fill. This is true because the frozen
layer closer to the injection location end has been in contact with the cold mold wall for a longer time than the frozen
layer around the end of fill.
Diagram of a developing frozen layer fraction.
The values given in the frozen layer fraction at end of fill plot are a percentage of the wall thickness. The blue areas with
a low value (0.0) are still molten along the cavity wall, and the red areas with a higher value (>0.5) have a high
percentage of frozen layer fraction. Areas that show a high percentage of frozen layer fraction will not pack as well as
section with a lower percentage of frozen layer fraction.
View of frozen layer fraction at end of fill.
Frozen layer fraction has significant effects on flow resistance of the plastic melt. You can reduce the fill time to reduce
the frozen layer fraction. Reducing the fill time also increases shear rates and shear stresses.

1)
2)
Clear Auto.
3)
4)
Click OK
5)
Flow
6)
Venting Pressure:
As the part is being filled the air inside the cavity will try to escape. If it cannot escape, burning or dieseling will create a
black, gray, or brown discoloration on the surface of the part. This is a result of gasses and volatiles becoming trapped
inside the mold. This causes the gasses to get compressed and heated during 1st stage injection (filling). These gasses
can be released through vents to avoid these discolorations.
Cooling Time:
The cooling stage is dedicated to reducing the material temperature to the deflection temperature under flexural load, the
ejection temperature. Typically, cooling time is 70% of the total cycle time.
Diagram of stage-times for the injection molding cycle.
Two factors that affect cooling time are melt temperature and mold temperature. Increasing either temperature typically
results in increased cooling time. Plastics require long cooling times because they are good insulators with low thermal
conductivities. Cooling time is proportional to the square of the part wall thickness, doubling the thickness quadruples the
cooling time. To reduce cooling times, you should make the part wall thickness uniform and as thin as safely possible.
View of cooling time.
To display a section view of cooling time at end of fill:

1)
2)
Click Cooling Time at End of Fill.
3)
The clipping plane mode of cooling time displays the required internal cooling times throughout the part wall (Solid
Mesh only).
Temperature at End of Cooling:

The temperature at end of cooling plot is based on when 90% of the part volume is below the material deflection
temperature under flexural load, the ejection temperature. If there is a large temperature distribution in thick regions of
the part, several problems may occur: sink marks, internal voids, or warpage. To reduce these problems, you should
design the part with a uniform wall thickness.
Non-uniform wall thicknesses are sometimes unavoidable, but solutions are available.
View of temperature at end of cooling.
To display a section view of temperature at end of cooling:

1)
2)
Click Temperature at End of Cooling.
3)
The clipping plane mode of temperature at end of cooling displays the internal temperature differential throughout the
Sink Marks:
Sink marks are depressions on the surface of an injection molded plastic part. The fundamental cause of sink marks is
that not enough polymer molecules have been packed into a part to compensate for the shrinkage that occurs. Thicker
sections of a part cool at slower rates than thinner sections, resulting in significant shrinkage in the thicker sections. After
the outer layer of plastic material has cooled and solidified, the molten core material must transfer heat through the
solidified plastic surface to the cavity wall. Plastic materials are insulators and do not transfer heat efficiently, which slows
down the cooling rate of the thicker core volumes. The more time a plastic material has to cool, the more the material will
shrink. The high degree of shrinkage in the core volume pulls the surface of the part inward, causing a depression on the
part surface.
You can use these design rules to minimize sink marks:

1)
2)
3)
4)
When safely possible, design with uniform part wall thickness.

Place injection locations at thicker sections of the part, so the thicker sections can be packed at higher
pressures.
Avoid using injection locations that are too small, which can prevent sufficient packing of the part cavity.
The thickness of ribs and bosses should be approximately 60 to 80 percent of the nominal wall
thickness.
View of sink marks.
Birefringence at End of Fill:
Multi-mode compressible Leonov model (nonlinear viscoelastic model) is used to predict flow induced residual stress.
Birefringence includes flow induced birefringence and thermal induced birefringence. Due to flow induced residual stress
and thermal residual stress, respectively, flow birefringence and thermal birefringence. The stress optical law is used to
predict birefringence, in particular, two different stress-optical coefficient is used to predict the flow-induced birefringence
and thermal birefringence, respectively. The birefringence components nxy, nyz and nxz are measured in the XY
plane, YZ plane and XZ plane, respectively, in the direction of the light.
Injection Location Filling Contribution:

When you only use one injection location, the cavity is filled by that one injection location. When you use multiple
injection locations, the cavity is partially filled with material entering from each of the injection locations.
View of injection location filling contribution. The phone housing was filled by two injection locations - one injection
location is located by the mouth piece and the second by the speaker. The green region was filled by the first injection
location, and the blue region was filled by the second injection location.
Note: As a result of using multiple injection locations, there will be a significant weld line located where the flow fronts
merge together. The weld line is at the interface of the green and blue regions.
To display weld lines:

1)
2)
Select Weld Lines.
View of weld lines from the use of two injection locations.
Ease of Fill:
You can use the ease of fill plot to determine whether the cavity fills successfully. The green regions indicate areas that
can be filled under normal injection pressures. The yellow regions indicate areas where the injection pressure exceeds
70 percent of the machines maximum injection pressure. The red regions indicate areas where the injection pressure
exceeds 85 percent of the machine maximum injection pressure.
View of ease of fill.
If you run a simulation on a part cavity only (with no runners), and the ease of fill plot has yellow or red areas, you should
try increasing wall thickness, moving the injection location, adding additional injection locations, changing the material or
adjusting the processing parameters to try to decrease the pressure require to fill.
Frozen Area at End of Fill:

The frozen area at end of fill plot indicates the regions of the part that have reached the material glass transition
temperature. The green regions (value 1) indicate that the material has reached the material glass transition
temperature. The red regions (value 0) indicate that the material is still above its glass transition temperature. The frozen
area at end of fill indicates the thickness of the frozen layer that builds up during fountain flow.
To display a section view of frozen area at end of fill:

1)
2)
Click Frozen Area at End of Fill.
3)
The clipping plane mode of frozen area at end of fill displays the internal temperature differential throughout the part wall
(Solid Mesh only). This plot also displays the frozen layer fraction at end of fill.
Clamping Force:
Clamping force refers to the force applied to a mold by the clamping unit of an injection molding machine. In order to
keep the mold closed, this force must oppose the separating force, caused by the injection of molten plastic into the
mold. The required clamping force can be calculated from the cavity pressure inside the mold and the shot projected
area, on which this pressure is acting. If X-Y plane is the parting plane, then Z-direction clamping force is the required
clamping force. The calculated clamping force can be used to select a proper machine that will prevent part defects, such
as excessive flash.

Fill Results - Solidworks Plastics

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Fill Results - Solidworks Plastics

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Fill Time:

To change the fill time:

Under INPUT, Process Parameters, double-click Fill Settings.

For Filling Time, enter a value in seconds.

Under RUN, double-click a fill option:

Click Yes, when prompted to replace the fill results.

Short shot resulting from an extreme flow length.

To reposition an injection location:

Under INPUT, Boundary Conditions, double-click Injection Location.

To delete the existing injection location, click either:

Click Yes, when prompted to delete an injection location.

In the Command Manager, click Mesh Model

To define the new injection location, click Add Injection Location

to display the mesh.

Under RUN, double-click a fill option:

Click Yes, when prompted to replace the fill results.

To display a section view of fill time:

Under RESULTS, double-click Fill Results.

Click Fill Time.

Click Clipping Plane Mode

Animation of Fill Time:

To animate the fill time:

Under RESULTS, double-click Fill Results.

To pause the animation, click Pause

To stop the animation, click either:

To slow down or speed up the animation, click Stop

, slide the Speed scale to the desired rate, and

To display the fill time manually:

Under RESULTS, double-click Fill Results.

Three manual display views of the fill time.

If an animation is currently playing, click Stop

before sliding the Max or Min scale.

Velocity Vector at End of Fill:

To display velocity vector at end of fill:

Under RESULTS, double-click Fill Results.

Select Velocity Vector at End of Fill.

View of the velocity vector at end of fill plot.

To display weld lines:

Under RESULTS, double-click Fill Results.

Select Weld Lines.

View of the weld line plot.

To display Air Traps:

Under RESULTS, double-click Fill Results.

Select Air Traps.

View of Air Traps superimposed over a Fill Time plot.

Pressure at End of Fill:

Uneven and even pressure at end of fill plots.

To reposition an injection location:

Under INPUT, Boundary Conditions, double-click Injection Location.

To delete the existing injection location, click either:

Click Yes, when prompted to delete an injection location.

In the Command Manager, click Mesh Model

To define the new injection location, click Add Injection Location

Under RUN, double-click a fill option:

Click Yes, when prompted to replace the fill results.

To change the fill time:

Under INPUT, Process Parameters, double-click Fill Settings.

For Filling Time, enter value for sec.

Under RUN, double-click a fill option:

Click Yes, when prompted to replace the fill results.

To display a section view of pressure at end of fill:

Under RESULTS, double-click Fill Results.

Click Pressure at End of Fill.

Click Clipping Plane Mode