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Injection Moulding Optimization
How Plaston and Gollmer perfected a multi-brand toolbox connector with Cadmould and Varimos AI.
Addressing the Challenge of Incompatibility
Construction professionals often rely on power tools from multiple manufacturers, each accompanied by its own transport box. While these boxes are designed for stacking, this functionality is typically limited to products from the same brand. Combining toolboxes from different brands results in inefficient transport, challenging storage, and unstable, potentially hazardous stacks. This raises a critical question: can toolboxes from different manufacturers be securely stacked? Swiss company Plaston sought to address this issue with an innovative solution—the Hybrid Adapter Plate project. This adapter was specifically designed to securely connect and stack toolboxes from various brands.
The Hybrid Adapter Plate, manufactured by Plaston, lets you stack toolboxes from various brands. It's compatible with Bosch L-Boxx and Sortimo L-Boxx. Plus, it allows for the first-time integration of DeWalt TStak, Makita Makpac, and Tanos Systainer.
Balancing Precision, Aesthetics, and Cost
To ensure the success of the adapter, Plaston needed to meet stringent quality and cost targets. To achieve this, they collaborated with Gollmer Formen, a leader in part and mold design, to address the project's unique challenges. This article explores how Gollmer applied advanced injection molding simulations to deliver a highly effective solution.
What Drove the Adapter's Design?
- Dimensional Precision: The adapter had to securely connect both the upper and lower toolboxes, making accurate measurements essential.
- Aesthetic Appeal: A clean finish without visible weld lines was imperative, along with compatibility with various color options.
- Cost Efficiency: Production processes for both the part and mold needed optimization to achieve cost targets.
- Time to Market: The design phase required swift execution, as the adapter was slated for inclusion in Engelbert Strauß's 2022 catalog.
Design and Simulation Phase
To align with aesthetic and cost objectives, Plaston opted for a central single valve gate design instead of a multi-gate hot runner system. This decision simplified handling of multiple colors and avoided weak points caused by weld lines. The gate was strategically positioned in the handle, ensuring structural integrity in the most critical area. The primary focus was to produce a dimensionally accurate, perfectly flat component. Plaston leveraged extensive design experience and iterative simulations to refine the product. Adjustments to wall thickness improved material flow, rib placements enhanced stiffness while minimizing warpage, and screw boss locations were optimized. These combined efforts established a solid foundation for the adapter’s design before advancing to the next stage.
Mold Development and Advanced Analysis
Plaston partnered with Gollmer Formen to finalize and manufacture the mold. “Simulation is integral to our process for evaluating and optimizing designs,” said Philipp Beckel, Project Manager at Gollmer. “Plaston’s preliminary work was excellent, but we identified minor warpage in one edge of the component and investigated ways to resolve it.” Gollmer prioritized adjusting injection parameters before considering geometric modifications. “We first explore whether adjusting temperatures and pressures can resolve the issue,” Beckel explained. “Only if necessary, do we discuss slight geometric changes. Thorough preparation and exploration of all parameter combinations are key.”
Systematic Variant Analysis
To speed up the process, Gollmer used a systematic approach instead of traditional trial-and-error methods. “We streamline the process using rapid variant analysis,” said Alexander Dangel, CEO of Gollmer. Gollmer leveraged Varimos AI, an advanced variant analysis tool integrated with SIMCON's Cadmould injection molding software. “Varimos AI allows us to efficiently explore solution spaces by running multiple simulations simultaneously,” explained Angela Kriescher from SIMCON. “Users define variables and their ranges, and the AI generates results, enabling real-time exploration of 'what-if' scenarios without needing new simulations.”
Varimos AI enabled a nearly 50% reduction in warpage by optimizing wall thicknesses after initial parameter adjustments showed minimal improvement.
Achieving Optimal Results
For the Hybrid Adapter Plate, Gollmer first used Varimos AI to vary injection pressures and temperatures. While parameter adjustments provided minor improvements, they were insufficient to fully resolve the warpage issue. The team then explored geometric modifications, hypothesizing that changes to the thickness of specific ribs could improve material flow and reduce warpage. “We set parameters for the wall sections that could be altered, and the range of adjustments,” Beckel explained. “This approach resulted in a significant breakthrough, reducing warpage by nearly 50%.”
We rely on Cadmould and Varimos AI not only for their unmatched precision but also for their efficiency and speed, which are essential in achieving success.
Alexander Dangel
CEO
Gollmer Formen
Flawless Production and Quick Time-to-Market
Once the part and mold design were optimized, Gollmer and Plaston proceeded to production. Mold tryouts confirmed the accuracy of the simulations, requiring only minimal adjustments. Serial production was launched without complications, with components meeting dimensional and quality specifications as predicted. CEO Alexander Dangel attributed the project's success to three key factors: a collaborative, trust-based partnership with Plaston, a robust working methodology that combined expertise with process parallelization; and the use of advanced technologies. “We rely on Cadmould and Varimos AI not only for their unmatched precision, but also for their efficiency and speed, which are essential in achieving success,” Dangel concluded.
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