The leading True 3D CAE simulation innovator, Moldex3D, in collaboration with its long-time partner SimpaTec, has unveiled expanded capabilities in the medical industry. The following case study is an example showcasing the practical applications of Moldex3D Multi-component Molding (MCM) and Powder Injection Molding (PIM) on artificial hip joints.
The artificial hip joint consists of three parts: a stem, a femoral head, and an acetabular prosthesis. In general, the life-cycle of such product is about 20 to 30 years. Therefore, material properties and durability play a key role in extending the life-cycle. Moldex3D and SimpaTec  looked to existing and new solutions to address this critical issue and came up with the innovative synergy of Moldex3D MCM and PIM.
Moldex3D MCM is designed to meet the increasing needs of multi-component injection molding, including insert molding, over-molding and multi-shot sequential molding. The module can accurately analyze the interaction behavior of different components and predict warpage caused by property mismatch of different materials.
Another unique simulation solution, Moldex3D PIM, is developed for optimizing products made from metal or ceramic feedstock. Moldex3D PIM can visualize the flow behavior of the feedstock consisting of powder and binder and predict potential black lines caused by non-uniform powder concentration for green parts.
The femoral head of the artificial hip joint consists of Ti-AI6V4.
The ceramic on the femoral head is produced via Powder injection molding (PIM).
The lower part of the stem is produced with another component via insert molding.
  
The maximal shear stress over the whole forming process can be reflected on the surface.
Besides investigating the properties of the materials, Moldex3D also provides detailed predictions on common powder injection molding problems, such as weld lines and non-uniform powder concentration distribution. Through accurate and precise simulation capabilities, Moldex3D comprehensively examine the effects of powder concentration, feedstock material properties, and processing conditions on cavity filling behaviors to help mold makers achieve optimal parts.Components with varying properties caused by the manufacturing process will be run through a structural simulation test to calculate the resulting stresses and the displacement from the required thermal stress. Based on the information obtained from the structural simulation, designers can quickly optimize parts. Due to the excellent properties in terms of bio-compatibility, ceramic materials have been proven to be an ideal materials for medical applications. For example, hydroxyapatite or tricalcium phosphate (TCP) has a high wear resistance, and ZrO2 or Ti-variations is durable with high stresses. In this case, the artificial hip joint consists of three components: the stem, femoral head, and acetabular prosthesis, which is made with a titanium compound (Ti-AI6V4). These three components can be precisely analyzed and verified with the Moldex3D MCM module. Moreover, under different loadings and stresses, optimizing the representation of mechanical properties with these components can also be obtained through the integration of ABAQUS and Moldex3D FEA Interface.
 Moldex3D PIM can simulate and optimize the injection molding of ceramic components.
The simulation analysis correlates with the reality very well.
The synergy of Moldex3D MCM and PIM modules has demonstrated how CAE simulation can optimize and enhance the quality of medical devices. For product designers, surgeons, and people with healthcare needs, the simulation techniques can boost the delivery of better healthcare products and further improve the quality of human life.
About SimpaTec
With years of practical experience in plastic injection molding, SimpaTec enjoys a notable reputation in Europe. Since 2004 SimpaTec has entered the world of plastics and started to offer diversified solutions and fresh inputs into molding simulation. With solid background in plastics and attentive support to customers, SimpaTec has made Moldex3D known as the world-class supplier of CAE software in Europe. For more information, please visit www.simpatec.com.
About Moldex3D
CoreTech System Co., Ltd. (Moldex3D) has been providing the professional CAE analysis solution “Moldex†series for the plastic injection molding industry since 1995, and the current product “Moldex3D†is marketed and supported worldwide. Committed to provide the advanced technologies and solutions for industrial demands, CoreTech System has extended its worldwide sales and service network to provide local, immediate, and professional service. CoreTech System provides the innovative simulation software to help customers troubleshoot from product design to development, optimize design patterns, shorten time-to-market, and maximize product return on investment (ROI). In addition to NX EasyFill Analysis, more advanced Moldex3D functions are also integrated with NX for packing, cooling and warpage optimization. Please find more details at www.moldex3d.com.
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