Material data for the simulation of thermosets – simple, practical, valuable
Do you process thermosets in injection molding? Then you know that the quality of the product depends heavily on material behavior—and that is often difficult to predict. This is exactly where our project comes in.
Unlike thermoplastics, for which material characterization and simulation are now standard practice, this is still often a complex and specialized process for thermosets. Our goal is to make material data determination simple and accessible so that we can create a robust material profile of your material with as few measurements as possible. To do this, we combine existing datasets with specific measurements of your material. The aim of the project is to establish a standardized process that leads to meaningful simulations of your product in a cost-effective and reliable manner. As a first step, your material is characterized and simulated at all relevant measurement points to establish the standard against which comparisons will be made. Subsequently, specific measurements are compared against existing standard datasets to determine which measurements are unnecessary and which are indispensable for obtaining a reliable simulation. This enables you to further develop your products in the future with less measurement effort and to move efficiently from material to simulation without time-consuming iterations. The key question is: “How can one achieve a robust simulation with as few and as cost-effective measurements as possible?”
This project is specifically tailored to SMEs that do not have their own development department for the complex analysis of their materials. However, larger companies are also welcome to participate.
Duration: 24 months, planned start Q3-4/2026
Material cards: Minimum of 2 per company, more possible.
Costs: approx. 15,000 EUR/year (for two material cards, the price scales with the number of material cards to be created)
Solution and results
What do we offer?
- Measurement & analysis of your materials:
- Analysis results – For daily use even outside of simulation
- Material card – What makes your material special, transferred to the simulation software
- Consulting on material optimisation – If the analyses reveal potential for optimising your material, we will be happy to advise you on material development.
- Simulation of your material in standardised geometries in the following steps:
- Filling simulation – Where do air pockets or weld lines form?
- Ventilation simulation – How can ventilation be optimised?
- Post-pressure simulation – Is shrinkage compensated correctly?
- Thermal simulation – What are the optimal cycle times and are there different cooling rates?
- Warpage analysis – Does the component deform after demoulding?
- Consulting & support – from the initial idea to application in operation.
Your advantages
- Your introduction to the world of simulation – First experiences with simulation software, laying the foundation for more complex simulations of your components; your material profile enables precise predictions for future projects
- The developed process allows for future simulations with reduced measurement requirements
- Insights gained through simulation reduce scrap and rework – thanks to precise predictions of your material
- Faster development – because you know how your material behaves.
- Competitive advantage – through digital process optimization.
- No prior knowledge required – we handle material selection and, if necessary, the simulation technology as well.
What is measured?
We record all relevant parameters: flow behaviour, curing, mechanical properties – and translate them into easy-to-use material cards for your simulation programme (e.g. Moldex3D, SIGMASOFT Virtual Moulding, IANUS Flow Space or Autodesk Moldflow).
What do you get?
Within this programme, at least two material cards are determined for your products. Simple test geometries are used to evaluate the optimal balance between measurement effort and simulation accuracy. Based on this, a recommendation for action is developed for material data determination and simulation in accordance with your individual resources for the topic.
Who is this interesting for?
For anyone who works with thermosets – whether in toolmaking, plastics processing or product development. Particularly suitable for companies that want to produce more efficiently and avoid errors – regardless of whether you already use simulations or only want to do so in the future.
General conditions
An SKZ pioneer project is industry-funded contract research on current and technologically valuable topics. The participating industrial companies share the costs and jointly benefit from the practical research results. As no public funds are acquired, the findings are not made public and remain exclusively reserved for the participating companies. At the end of the project, you have a choice: keep your results exclusive – or opt for data exchange and benefit from the combined knowledge of all participants who have also chosen this option. The project is scheduled to start in Q3-4 2026 with a project duration of two years and a participation fee of approximately 15,000 EUR per year (for two material cards).
Interested?
Then get in touch with us – we will show you how simple and effective material data can be. Your enquiry is non-binding. We would be happy to advise you personally on the planned process and further details.
Did you know?
You can claim research services for tax purposes under the Research Allowance Act!
You can find out about the legal framework that applies to this on the website of the Federal Ministry of Finance. We would be happy to advise you on further funding opportunities.
Project parameters: Pioneering project
Duration: 24 months, planned start Q3-4/2026
Material cards: Minimum of 2 per company, more possible.
At the end of the project, each participant can decide whether to keep the material cards exclusively for themselves or to opt for data exchange and gain access to all material data from participants who have also chosen this option (with 8 project participants with two material cards who wish to exchange data, this corresponds to 16 material cards for these project participants).
Costs: approx. 15,000 EUR/year (for two material cards; the price scales with the number of material cards to be created)