These slides were presented at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

The injection molding process for PET (Polyethylene Terephthalate) preforms is vital to producing high-quality packaging materials. However, manufacturers (e;g: Engel global, Husky Technologies, ..) often face challenges such as uneven cavity filling, inefficient cooling, and defects like warping, sink marks, or voids. Addressing these issues traditionally involves extensive trial-and-error experiments, which can be both costly and time-consuming. This study explores computational fluid dynamics (CFD) modeling as a modern alternative to overcome these limitations, providing a deeper understanding of the molding process and guiding optimization efforts. Through advanced simulations, the study investigates critical aspects of preform production, including melt flow dynamics, pressure distribution, thermal gradients, and solidification behavior. These factors are essential for ensuring consistent product quality while reducing cycle times. By examining how mold design, gate placement, injection speed, and cooling configurations influence the process, the research identifies strategies to minimize defects and improve efficiency. One significant finding is the importance of cooling optimization in achieving uniform heat dissipation. Proper cooling ensures even solidification, which directly affects preform strength and appearance. Similarly, the study reveals how balanced gate designs improve material flow, reducing localized overheating and material degradation. These insights highlight the potential of computational tools to predict process outcomes under various conditions, eliminating the need for costly physical prototypes. This work also emphasizes the environmental and economic benefits of computational simulations. By reducing energy consumption, material waste, and experimental iterations, manufacturers can achieve more sustainable production practices. The results contribute to bridging a significant research gap in PET preform molding, offering a practical framework for improving process efficiency and precision. In summary, this study demonstrates how computational methods can revolutionize PET injection molding by addressing long-standing challenges with precision and efficiency. These tools empower manufacturers to deliver consistent, defect-free preforms while adapting to the evolving demands of global markets. The ability to simulate and optimize every aspect of the process represents a paradigm shift, transforming injection molding into a faster, more cost-effective, and environmentally responsible manufacturing solution. This work not only bridges a critical research gap but also sets the stage for further innovations in polymer processing and sustainable industrial practices.