Warpage of injection-moulded thin plates : numerical evaluation of simulation strategies and experimental validation

Kastelic, Tomaž (author), Mole, Nikolaj (author), Cafuta, Gašper (author), Starman, Bojan (author), Halilovič, Miroslav (author)

This study presents an experimental and numerical investigation of warpage in injection-moulded ABS plates, with emphasis on the influence of modelling assumptions and residual stress development on warpage prediction. Two sets of processing conditions with different mould-temperature balances were investigated experimentally, and warpage was measured using a coordinate measuring machine (CMM). Filling and packing were simulated using Moldex3D, while warpage was predicted using two integrated Moldex3D solvers and a coupled Moldex3D–Abaqus thermomechanical approach. Although identical thermal input data were used, the three approaches produced noticeably different warpage predictions. The Moldex3D enhanced solver consistently over-predicted warpage magnitude, while the Moldex3D nonlinear solver captured the nonlinear effects but showed unrealistic localised deformation. The thermomechanical approach predicted the warpage shape more accurately for both parameter sets and showed the closest overall agreement with the experimental results.

• Language: English
• Keywords: warpage, injection moulding, thermomechanical simulation
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2026
• Number of pages: 28 str.
• Numbering: Vol. 18, issue 11, art. 1310
• PID: 20.500.12556/RUL-182893
• UDC: 004.942:544.1
• ISSN on article: 2073-4360
• DOI: 10.3390/polym18111310
• COBISS.SI-ID: 279534851
• Publication date in RUL: 27.05.2026

Record is a part of a journal

• Title: Polymers
• Shortened title: Polymers
• Publisher: MDPI
• ISSN: 2073-4360
• COBISS.SI-ID: 517951257

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Keywords: zvijanje, injekcijsko brzganje, termomehanska simulacija

Projects

• Funder: ARIS - Slovenian Research and Innovation Agency
• Project number: P2-0263
• Name: Mehanika v tehniki

• Funder: ARIS - Slovenian Research and Innovation Agency
• Project number: L2-3172
• Name: Razvoj tehničnih smernic za štirislojne zasteklitve