Optimization : Design - Lightening

Thanks to a new generation of extremely high-performance digital tools (modeFRONTIER, COMSOL Multiphysics, Exstream etc.) and new methods of working, PEP is supporting its clients in optimizing the design of injected plastic products and tools (especially thermal optimization).

In the present example, PEP worked on optimizing a food container (made of PP) for cream, in order to reduce its mass and minimize distortion during the thermo-sealing process.

The constraints of this project were to preserve the container's volumetric capacity, ensure its mechanical resistance during sealing and squeezing, at the same time as keeping existing production techniques.

With the help of modeFRONTIER (multiobjective and multidisciplinary optimization software), by integrating and combining software packages for CAD (Solidworks) structural calculation (ANSYS) and rheological simulation (Moldflow), and after 11 hours of calculations, PEP was able to define an optimal design that meets the specification requirements. In particular, the design:

• reduces plastic mass by 17%
• reduces distortion during sealing by 17% (while respecting the material's elastic limit)

This innovative methodology, which has produced real economic gain for the client company, is also an exercise in ecodesign (reducing mass and therefore material, as well as having an impact on the transportation and recycling of the container).

The field of design optimization has vast scope: PEP has considerable experience in this respect, whether in packaging or technical components, the health or cosmetics sectors.   

Research carried out in partnership with EnginSoft and RG Plastiques (GPACK Group).