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There’s a persistent myth in injection molding that goes something like this: “If the part is warping, just add ribs and it will flatten out.” It sounds logical. Ribs add stiffness, stiffness fights deformation — therefore: flatter part, right? Well… sometimes. But just as the Earth isn’t flat, your part won’t magically become flat just because you threw a rib pattern at it. In many cases, ribs can actually increase warpage if they’re not designed with the material and flow b

When molders troubleshoot cooling issues, they tend to focus on channel layout, Reynolds numbers, turbulence targets, or temperature deltas. But there’s a missing piece that quietly undermines many well-designed systems: the effect of the water manifold. In fact, most Moldflow simulations don’t model the manifold at all—and in many cases, that’s perfectly acceptable. But it does require an experienced engineer to interpret the results, or you risk making decisions based on a

Plastic injection molding has revolutionized manufacturing, but appearance issues continue to be one of the biggest headaches for engineers, second only to warpage. These blemishes don’t just affect aesthetics—they can impact part strength, customer trust, and production timelines. In a recent session of Ask the Moldflow Experts, Tim Lanes, Director of Engineering at CAE Services, shared his deep expertise on how simulation tools like Moldflow can help prevent and solve these