Direct search-based automatic minimization of weldlines in injection molded parts

This paper deals with an automated design methodology for minimization of weldlines by optimizing the design spaces. Weldlines are quantitatively evaluated based on their length and location and the melt front movement with the aid of commercial injection molding simulation software which provides an integrated analysis. A combined implementation of the Complex method and injection molding simulation was developed to reduce and relocate weldlines. Gillette's deodorant base was chosen for the weldline minimization. Reduction and relocation of weldlines for the deodorant base prevented the cracking problem in the original design. The results of simulation based on the automated design methodology agree well with the experimental findings.