Slurry Flow Simulation and Mold Filling Analysis in Molded Pulp: Predicting Fill Before You Cut Steel

Molded-pulp defects like thin walls and weak corners often trace back to how slurry fills the mold. Flow simulation predicts fill behavior, drainage, and thickness distribution before steel is cut, reducing expensive mold trials and getting first articles right faster.

The Scenario: Three challenges in mold filling

Molded-pulp mold filling faces three challenges:

Pain Points

• Slurry flows unevenly through complex geometry, leaving thin walls and voids in deep or fine features;
• Drainage rate varies across the mold, causing inconsistent density and thickness;
• Trial-and-error mold corrections cost money and delay ramp-up.

The Solution: Three simulation-driven measures

Flow simulation offers three measures:

1. Slurry flow and fill prediction Simulate slurry flow to predict where walls will be thin or voids will form before tooling.

2. Drainage and thickness mapping Map drainage rate and thickness distribution to balance density across the part.

3. Mold iteration in software Test vent and screen placement digitally to cut physical mold trials and speed first-article approval.

The Result: Right first time, lower tooling cost

With simulation, first articles come out closer to spec and mold rework falls. Predicting fill up front saves tooling cost and shortens time-to-market.