Language IconSearch Icon
Interior of finished car outdoors with sunset sky in the distance

Case Study

EASi Strengthens Product, Drives Cost Savings

A manufacturer was experiencing a crack on the injection mold tooling of major parts, costing millions of dollars in tool repair. The company asked EASi to build a stronger product.

The client and challenge
Our customer, a top U.S. original equipment manufacturer (OEM), was experiencing a crack on the injection mold tooling of major parts, such as the instrumentation panel. The cost to the company was significant — millions of dollars in tool repair, in addition to shut-down costs.

The EASi solution
EASi’s mission was to predict and improve the mold tool life to avoid field failures during production.

Using an established team of automotive computer-aided engineering (CAE) resources in its Troy, Mich., delivery center, EASi established a methodology to predict the real-world longevity performance of the mold tool. EASi utilized its expertise in mold tool design and used material S-N curves and Moldflow techniques, which ultimately allowed the team to identify failure modes of the mold structures with field and tool process inputs.

The results
EASi’s analysis played key role in identifying and providing cost-effective design recommendations to enhance the longevity of the mold tools. This support allowed the customer to realize a significant cost savings ($500,000 to $700,000 per mold) in tool repair, in addition to the reduction in shut-down costs.

Expertise
Coupled Structural Thermal solution using LS-DYNA solver
Methods for tool modeling and fatigue longevity prediction