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1Project: STX-50-001-2012

Engineering with a Purpose

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2Project: STX-50-001-2012

01/07/2013

Prepared for:

Doug HeplerPolyshot Corporation

West Henrietta, New York

Polyshot Brazed Core Mold Flow Analysis Project

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3Project: STX-50-001-2012

01/07/2013Project Statement

The purpose of this mold flow study was to evaluate the manufacturing performance change in a single cavity simple Cap mold with conformal cooling utilizing Polyshot’s brazed core technology and one utilizing a standard baffle design.

Both scenario’s inputs were identical with the exception of the mold insert and cooling configuration.

Baffle Conformal

Cap

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4Project: STX-50-001-2012

01/07/2013Finite Element Mesh – Tetra / Prismatic Mixed

622,301 Part elements1,074,897 Cooling elements2,949,503 Mold elements

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5Project: STX-50-001-2012

01/07/2013Material Properties (PP – Sabic 575P)

Units = English

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6Project: STX-50-001-2012

01/07/2013Processing Conditions

Units = English

80% of EOF Pressure

70% of machine capacity of 20 ksi

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7Project: STX-50-001-2012

01/07/2013Filling Pattern @ EOP

Animated Animation will play when shown as a slide show.

Baffle Conformal

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8Project: STX-50-001-2012

01/07/2013Part Temperature at End of Packing Phase

Baffle Conformal

36% lower

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9Project: STX-50-001-2012

01/07/2013Part Temperature at End of Cooling Phase

Baffle Conformal

38% lowerDenotes a faster

cycle

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10Project: STX-50-001-2012

01/07/2013Mold Temperature at End of Cooling Phase (Cross Section View)

Baffle Conformal

Showing much cooler mold inserts when

results are scaled to identical values

Temperature difference resulted in a 39%

reduction in cycle time.

Req’d Cooling Time

3.1 sec

Req’d Cooling Time

1.9 sec

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11Project: STX-50-001-2012

01/07/2013Mold Temperature at End of Cooling Phase – Detail View

Baffle Conformal

Showing much cooler mold inserts when

results are scaled to identical values

Temperature difference resulted in a 39%

reduction in cycle time.

Req’d Cooling Time

3.1 sec

Req’d Cooling Time

1.9 sec

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12Project: STX-50-001-2012

01/07/2013Coolant Temperature at End of Cooling Phase

Baffle Conformal

99% lower temperature rise in coolant during the

cooling phase. Greater cooling

efficiency.

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13Project: STX-50-001-2012

01/07/2013Coolant Pressure at End of Cooling Phase

Baffle Conformal

98% higher coolant pressure

during the cooling phase. Greater

cooling efficiency.

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14Project: STX-50-001-2012

01/07/2013Total Displacement (Warpage) after Ejection at Room Temp

Baffle Conformal

5X Magnification 25% lowertotal warpage

(all effects included)

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15Project: STX-50-001-2012

01/07/2013Total Displacement (Warpage) after Ejection at Room Temp

Baffle Conformal

10X Magnification 25% lowertotal warpage

(all effects included)

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16Project: STX-50-001-2012

01/07/2013Total Displacement (Warpage) after Ejection at Room Temp

Baffle Conformal

5X Magnification 25% lowertotal warpage

(all effects included)

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17Project: STX-50-001-2012

01/07/2013Contact Information

Robert A. HickmanPresident

Shadow Polymer Industries, Inc.Houston, Texas

(281) 789-7520 office

(330) 224-5640 cell

Rob@shadowpolymer.com

For more information, visit us online at:

www.shadowpolymer.com