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GAME ON! The 2022 SimTech Injection Molding Monthly Challenges Are in Play.

New this year! Bring the Fun to Your Plant. Encourage a friendly in-plant competition, and every month, we’ll spotlight the winning company (you must have three or more players from the same company in order to win and earn a score). BONUS! Each participating company will have a chance to become the TOP MOLDING COMPANY of 2022 at the end of the year.

Current Molding Champ: Alexandru Crai of OMS Besser Group is the current SIMTECH™ INJECTION MOLDING CHAMPION! Congratulations Alexandru! Well done. He’s the one to beat for 2022.

 


What Are the Challenges?

Each month competitors are tasked with molding a defect-free part, within specifications, with the fastest cycle time using Paulson’s online virtual injection molding machine, SimTech™.  Learn more here.

Get on the list and have the latest challenge releases sent to your in-box.  Sign Me Up!

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THE MAY SimTech Injection Molding CHALLENGE is OPEN!

Open:  May 12, 2022
Closes: April 19, 2022 
Difficulty: High-Difficulty
Scoring:
“Efficiency Scoring” 

Scenario 

In this month’s challenge you will be molding a Frame Polypropylene (PP) using a 300-ton molding machine equipped with a screw designed for semi-crystalline material. We will again be using the “Efficiency” scoring method. The part is considered “thick-walled” and PP is a semi-crystalline material.  

 Your job is to correct any machine alarms, correct any part problems, and adjust the machine settings to get the best molding efficiency percentage. The quoted (standard) cycle time for this job is 33.0 seconds.  

 You will see under the Cycle Results, the “Mold Full at VPT” is 92.02. This VPT setting is not optimized. You do have to optimize the VPT setting.  The VPT should occur when the mold is between 94% – 96% full. The part has some problems. The part is undersized, has sink marks, burn marks, and shows signs of warping. Additionally, there is a machine alarm of “no cushion” that must corrected. Notice the part is not within the part specification of 12.000” (304.8 mm) in length. The part has a precision dimensional specification of +/- 0.002 in (0.005 mm) 

Burn Marks should be corrected first. Burn Marks have a high probability of creating tool damage and must be addressed as a priority. 

Our molding experts have achieved an efficiency score of 115% plus. Can you eliminate all problems and mold better than a 33.0 second cycle? Can you beat the 115% plus efficiency score?  

Additional Conditions

  • The minimum Melt Temperature of 389°F (198.3 C) is allowed for Polypropylene.
  • The minimum Mold Temperature allowed is 70°F (21.1C).
  • The standard (quoted) cycle time for this job is 33.0 seconds.

NOTE: In order to receive a score, all of the following conditions must be met: 

  1. No part problems or alarms 
  2. Part must be molded with a precision tolerance on the length. (+/- 0.002 in.) 

 The following “Best Practices” must be met: 

  1. Mold Full at VPT must be 94% – 96% 
  2. Cushion Size must be less than 10% of the Screw Back Distance 
  3. Melt Temperature must be within ± 2°F of the Nozzle and Front Zone Temperature 

Get Started

  1. Log into your SimTech account at www.paulsonsimtech.com
  2. Click Login or Register (if 1st time in SimTech)
  3. Click on “Run Challenges”
  4. Choose “May Challenge 2022” and click on “Run”
  5. Click the “Cycle” button to begin to see the results of the present setup. Start to make controls changes, one at a time, and then click “Cycle”.

NOTE: Only make one control change at a time and then click the “Cycle” button to see the effects of that particular control change. This is the best practice to follow when making any control changes whether it be in SimTech or on an actual molding machine.

What's SimTech & How Do I Use It?

Throughout the challenges, participants will be added to the Challenge Leaderboard posted here.

View the Challenge Leaderboard by clicking on the #1 badge below6

What molders have to say about Paulson Training products:

Very informative. You will understand how material affects molding!

Cynthia Miller

“Great, excellent, easy-to-use, interesting, challenging, engaging, organized, informative, helpful, solutions oriented, accurate, effective, flexible, confidence building and worthwhile.”

John W. Stebelton

“Paulson has built confidence, a sense of accomplishment & pride in our workers, something they can take to the floor and apply!”

Gene Shuret

Have fun testing your molding skills using Paulson’s most advanced injection molding simulator SimTech™ no other plastics simulator has the ability to process over 26 million molding simulated calculations. Good Luck! May the best molder win!

Get on the list now to have the latest challenge releases sent to your inbox.  Sign Me Up!

SimTech™ Challenge FAQs 

Click each icon below for answers

How does the Challenge work?

Each month, Paulson’s molding experts will devise a new molding problem for you to solve. For example, you will be challenged to mold a specific part without any defects and with the fastest cycle time. Once you’re in SimTech™, you will see the virtual control panel where you will be able to view the part, the plastic, and the machine specs in order to “mold” your part effectively. Bonus points are given, BUT if you need to access “hints,” points will be lost. Besides winning, the actual goal here is to learn.

Will I win anything?

Yes! Each month you’ll have a chance at winning a 1st, 2nd, or 3rd-place including eligibility to be crowned TOP INJECTION MOLDER! Plus, each participant can earn a spot on Paulson’s SimTech Challenge leaderboard. Paulson’s SimTech Challenges are ideal for in-plant competitions too. Gather your team together for a friendly internal competition all while gaining critical thinking and key troubleshooting skills. Get Ready! Who will be this year’s SimTech Injection Molding Champion?

What is SimTech?

SimTech™ is Paulson’s most advanced, proprietary, injection molding simulation tool. It’s a powerful online engine built on decades of complex mathematical equations of plastic and process analyses that combine both molding theories and practices. All together, SimTech™ has the outstanding capability to process some 20 million calculations per simulated cycle, and check all possible simulations against possible errors. No other injection molding simulation tool is more powerful!

How do I enter?

In order to participate in the monthly challenges, you MUST register by filling out the form. You will then receive email alerts when each challenge is released. Act now and be ready to take the challenge.

May the Best Molder Win!

Have more questions? Call us! 800-826-1901.

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