Injection molding warp prediction

A method comprising:

• obtaining, by a numerical injection molding simulation program, a three-dimensional model of a mold and measured shrinkage data for at least one material;
• predicting, by the numerical injection molding simulation program, an amount of warpage for a part manufactured using the mold by computational simulation of an injection molding process, wherein the computational simulation uses an internal residual stress model for the part that uses calibrated values for a coefficient of thermal expansion and for a Poisson's ratio of the at least one material, in at least one direction, for at least thermal stress due to cooling and pressure compensation during a packing or holding phase of the injection molding process, wherein the calibrated values are calibrated in accordance with the measured shrinkage data for the at least one material;
• and
• providing the amount of warpage predicted for the part manufactured using the mold.

A system comprising:

• one or more data processing apparatus;
• and
• a non-transitory computer-readable medium tangibly encoding a numerical injection molding simulation program operable to cause the one or more data processing apparatus to perform operations comprising
• obtaining a three-dimensional model of a mold and measured shrinkage data for at least one material,
• predicting an amount of warpage for a part manufactured using the mold by computational simulation of an injection molding process, wherein the computational simulation uses an internal residual stress model for the part that uses calibrated values for both a coefficient of thermal expansion and an elastic modulus of the at least one material, in at least one direction, for at least thermal stress due to cooling and pressure compensation during a packing or holding phase of the injection molding process, wherein the calibrated values have been calibrated in accordance with the measured shrinkage data for the at least one material, and
• providing the amount of warpage predicted for the part manufactured using the mold.

A system comprising:

• one or more data processing apparatus;
• and
• a non-transitory computer-readable medium tangibly encoding a numerical injection molding simulation program operable to cause the one or more data processing apparatus to perform operations comprising
• obtaining a three-dimensional model of a mold and measured shrinkage data for at least one material,
• predicting an amount of warpage for a part manufactured using the mold by computational simulation of an injection molding process, wherein the computational simulation uses an internal residual stress model for the part that uses calibrated values for a coefficient of thermal expansion and for a Poisson's ratio of the at least one material, in at least one direction, for at least thermal stress due to cooling and pressure compensation during a packing or holding phase of the injection molding process, wherein the calibrated values have been calibrated in accordance with the measured shrinkage data for the at least one material, and
• providing the amount of warpage predicted for the part manufactured using the mold.